Tech. Specifications (Civil & HM)

Mountain Energy Corporation
SUPER HYDRO ELECTRIC PRIVATE LIMITED KHIRAO GANGA HYDRO ELECTRIC PROJECT (2 2.0 MW) UTTARAKHAND TENDER DOCUMENT FOR CIVIL & HM WORKS
VOL. 2 DESIGN MEMORANDUM & TECHNICAL SPECIFICATIONS
Consultants: M/s Halcrow Consulting India Private Limited B-11, 2nd Floor, Sector-4, Noida-201301. (Uttar Pradesh) Tel.: +91-120-4682500 Fax: +91-120-468-2534 www.halcrow.com
Khiraoganga Small Hydro Electric Project
Tender Documents Specifications: Volume II A Civil
KHIRAOGANGA HYDRO ELECTRIC PROJECT
Volume II A DESIGN MEMORANDUM AND TECHNICAL SPECIFICATION FOR CIVIL WORKS
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INDEX PART 1: GENERAL AND PRELIMINARY............................................................1 101 Description of the Area..................................................................................1 102 General Description of the Project.................................................................1 103 Scope of work ................................................................................................1 104 Drawings ........................................................................................................2 105 Site Installations.............................................................................................2 106 Construction Power........................................................................................2 107 Water Supply .................................................................................................3 108 Camps and Services .......................................................................................3 109 Communications ............................................................................................4 110 Waste Disposal...............................................................................................4 111 Materials on and under the Site .....................................................................4 112 Boundaries Cut Through................................................................................4 113 Drains, Streams Watercourses etc .................................................................4 114 Compensation Water and Flow Past Structure ..............................................4 115 Keeping Works Free from Water...................................................................5 116 Slips ...............................................................................................................5 117 Protection of Completed Work ......................................................................5 118 Traffic ............................................................................................................5 119 Damage to Access Roads...............................................................................5 120 Setting Out .....................................................................................................5 121 Surface and River Bed Levels .......................................................................6 122 Testing Laboratory.........................................................................................6 123 Safety of Personnel ........................................................................................6 124 Protection of the Environment .......................................................................6 125 Interference with Existing Works ..................................................................7 126 Photographs ...................................................................................................7 PART 2: WORKMANSHIP AND MATERIALS ....................................................9 201 Workmanship and Materials in General ........................................................9 202 Inspection of Materials ..................................................................................9 203 Tolerances ....................................................................................................10 PART 3: EXCAVATION AND EARTHWORKS..................................................11 301 Definition of Earthworks Material...............................................................11 302 Site Clearance ..............................................................................................11 303 Excavation General...................................................................................11 304 Excavation Beyond True Lines and Levels .................................................12 305 Approval of Excavations .............................................................................12 306 Excavations for Structures ...........................................................................13 307 Disposal of Surplus Excavated Materials ....................................................13 308 Procurement, Storage and Handling of Explosives .....................................13 309 Magazines ....................................................................................................14 310 Blasting ........................................................................................................14 311 Underground Excavations............................................................................15 312 Rockbolting..................................................................................................16 Page ii
313 Steel Rib Supports .......................................................................................18 314 Shotcreting ...................................................................................................19 315 Fill ................................................................................................................21 316 Backfill to Structures ...................................................................................22 PART 4: CONCRETE...............................................................................................23 401 Cement .........................................................................................................23 402 Storage of Cement........................................................................................23 403 Fine Aggregate.............................................................................................23 404 Coarse Aggregate.........................................................................................24 405 Testing of Aggregates ..................................................................................26 406 Aggregate Reactivity Potential ....................................................................26 407 Water............................................................................................................26 408 Admixtures...................................................................................................27 409 Concrete Mixes ............................................................................................27 410 Plum Concrete..............................................................................................27 411 Concrete Mix Designs .................................................................................28 412 Trial Mixes...................................................................................................28 413 Works Test ...................................................................................................28 414 Test Failure ..................................................................................................29 415 Workability ..................................................................................................29 416 Concrete Returns and Records.....................................................................29 417 Batching and Mixing of Concrete................................................................30 418 Concrete Placing ..........................................................................................30 419 Concrete Placing Equipment .......................................................................31 420 Time for Placing Concrete ...........................................................................31 421 Compaction ..................................................................................................31 422 Placing in Inclement Weather......................................................................31 423 Placing in High Temperature .......................................................................31 424 Formwork.....................................................................................................31 425 Preparation of Formwork.............................................................................32 426 Classes of Finish ..........................................................................................32 427 Removal of Formwork.................................................................................33 428 Construction Joints ......................................................................................33 429 Movement Joints..........................................................................................34 430 Steel Reinforcement.....................................................................................35 431 Storage of Reinforcement ............................................................................36 432 Cover to Reinforcement...............................................................................36 433 Curing and Protection ..................................................................................36 PART 5: MASONRY AND STONEWORK ...........................................................38 501 Stone ............................................................................................................38 502 Masonry .......................................................................................................38 503 Random Rubble Masonry ............................................................................39 504 Masonry Lining to Waterways ....................................................................39 505 Stone Masonry Armouring to Weirs............................................................39 506 Dry Rubble Walling.....................................................................................41 507 Hand-placed Rubble Filling.........................................................................41 508 Rubble Filling ..............................................................................................41
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509 Gabions ........................................................................................................41 510 Rock Armouring and Rip-Rap .....................................................................42 511 Filter Fabric / Geotextile..............................................................................43 512 Gravel Filter .................................................................................................43 513 Stone Pitching ..............................................................................................43 PART 6: ROADWORKS ..........................................................................................45 601 Sub-grade Preparation..................................................................................45 602 Granular Sub Base (GSB)............................................................................45 603 Water Based Macadam (WBM) Road Surfacing.........................................45 604 Road Maintenance .......................................................................................46 PART 7: CULVERTS & DRAINAGE.....................................................................47 701 Culvert Material...........................................................................................47 702 Unloading and Laying out Pipes..................................................................47 703 Laying and Jointing Pipes............................................................................47 704 Installation ...................................................................................................47 705 Subsurface Drainage Slotted Plastic Pipework.........................................48 PART 8: BUILDING FINISHING WORKS ..........................................................49 801 General.........................................................................................................49 802 Applicable Codes and Specifications ..........................................................49 803 Waterproofing Work....................................................................................50 804 Damp Proof Course......................................................................................51 805 Cement Plaster .............................................................................................51 806 Cement Pointing...........................................................................................52 807 Mosaic Flooring ...........................................................................................52 808 Woodwork in Doors, Windows, Partition, Louvres, Railing etc .................52 809 Glazing and Metal Doors and Windows......................................................54 810 Painting ........................................................................................................55 811 Water Supply and Sanitary Works...............................................................55 812 Electrical Works ..........................................................................................56 813 Roof sheets and vertical cladding ................................................................57 814 Fencing.........................................................................................................57 PART 9: EARTH MAT.............................................................................................58 901 General Description .....................................................................................58 902 Earth Rods....................................................................................................58 PART 10: STEELWORK .........................................................................................59 1001 Hot Rolled Steel.......................................................................................59 1002 Surface Condition ....................................................................................59 1003 Structural Fasteners..................................................................................59 1004 Welding Consumables .............................................................................60 1005 Corrosion Protection System ...................................................................60 1006 General Workmanship .............................................................................60 1007 Welding Workmanship ............................................................................61 1008 Bolting Workmanship..............................................................................62 1009 Erection of Steelwork ..............................................................................62 1010 Protective Treatment - General................................................................62 1011 Protective Treatment - Particular.............................................................63 1012 Painting Handrails....................................................................................63
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Appendix A: Primary Survey Stations ...................................................................64 Appendix B: Table of Tolerances .............................................................................65
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PART 1: GENERAL AND PRELIMINARY

101 Description of the Area
1) The proposed Khiraoganga hydropower project is located near Benakuli village, Dist. Chamoli, Uttarakhand. The project is located on the river Khiraoganga on Rishikesh- Badrinath road and is at a distance of about 298 km from Rishikesh. The Powerhouse site is proposed to be located on the left bank of river Khiraoganga . Diversion weir of the scheme is located about 0.6km upstream from confluence of Alaknanda; Khiraoganga at Benakuli. 2) The topography of the project area is typically undulating, Himalayan with deep river valleys and high ridges. The left bank of the river has thickly wooded forest, and has a mixed usage as forest land as well as human habitation. Part of the right bank area mostly belongs to private owners and is used for farming and rest of the area is either barren or sparsely covered with shrubs or a forestland. 102 General Description of the Project
1) There is a motorable access road from Rishikesh to Badrinath via Srinagar, Ruderparyag, Chamoli, Joshimath, Lambagarh and to Benakuli .River Khirao originates in the glacier regions of upper Himalayas. At present the project site is approachable through a pedestrian suspension bridge about 50 meters down stream of confluence of river Khirao and Alakananda.The barrage site of Vishnu Prayag HEP is around 700 meters down stream from the confluence point. A path way constituted the major approach for people of Lambagarh who shift their cattle during summers to their summer village Khirao which is approximately 1.5 km from suspension bridge.
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Scope of work
1) The Works to be constructed under the Contract comprise the following components: 1) Diversion Weir and Intake structure on the Khiraoganga River 2) Intake Channel 3) Desilting Basin 4) Power Channel 5) Tunnel in rock 2.5m diameter D shaped with concrete lined approximately 550m long. 6) Surge Tank 8m dia reinforced concrete surge tank. 7) Penstock Valve House and Penstock Excavation in overburden with rock outcrops for construction of penstock saddle support, crossings and anchor blocks, Concrete framed valve house with boulder masonry or brickwork infill walls. Casting in penstock pipe and transition (penstock, valves and associated steelwork supplied and installed by others). 8) Surface Power House, Transformer and Switchyard Construction of surface Power House and Tail Race and Surface Transformer and Switchyard civil works (Electromechanical supply and installation by others). Page 1
2) In addition, the Contractor shall construct such accommodation, plant yard workshops, office, housing and camps for himself, his staff and employees as he considers appropriate. 3) The scope of work shall also include all general and preparatory works and shall include work of any kind necessary for the due and satisfactory construction, completion and maintenance of the Works in accordance with the Drawings and these Specifications and further drawings and orders that may be issued by the Engineer from time to time. 104 Drawings
1) The Works are shown on the Contract Drawings in Section 6 - Drawings 2) Two copies of the Construction Drawings, shall be furnished free of cost to the Contractor by the Engineer progressively according to the work programme submitted by the Contractor and accepted by the Engineer. Drawings for any particular activity shall be issued to the Contractor at least 30 days in advance of the scheduled date of the start of the activity. 3) Examination and /or approval by the Engineer of any drawings or other documents submitted by the Contractor shall not relieve the Contractor of his responsibilities or liabilities under the Contract. 105 Site Installations
1) The extent of the areas of land which are to be made available by the Employer for the use of the Contractor are as shown on the Drawings. 2) The Contractor shall be responsible for obtaining, at his own cost, any additional areas of land he may require for his own temporary facilities or for the disposal of spoil. Such areas shall be deemed to be part of the site. 3) Prior to the commencement of any work at the Site and not later than 28 days after the Date of Commencement, the Contractor shall submit to the Engineer for approval detailed drawings showing the locations and details of his proposed installations, facilities, plant, stockpiling and "waste" areas in order that such proposed installations, facilities etc may be co-ordinated with the requirements of the Engineer and other Contractors. The Contractor shall not commence any of the proposed installations/facilities until the Engineer's approval has been obtained. Any subsequent changes must be the subject of the Engineer's prior approval . 106 Construction Power 1) The Contractor shall be responsible for providing construction power for his own use including all his site installations, offices, accommodation areas, workshops and laboratory.
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2) The Contractor shall present drawings and plans of the installations to the Engineer and obtain his approval prior to the commencement of the work. 3) The Contractor shall be responsible for providing lighting and ventilation at all working areas as required. 107 Water Supply
1) Water from the Khiraoganga River is suitable for construction purposes. 2) The Contractor shall provide water for the Works, including potable water. This provision shall include the construction of necessary reservoirs and piping to cover all demand peaks at any time. 3) Prior to any installation, the Contractor shall submit to the Engineer for his approval a detailed description of the planned water supply system. The quality of, and the designed pressure in, the water supply system shall be subject to the prior approval of the Engineer. 108 Camps and Services
1) The Contractor shall provide camps for boarding, lodging and medical care for his own personnel and those of his subcontractors. 2) The standards and regulations presently in force in India in respect of the treatment of personnel, sanitation and accident prevention, shall duly be taken into account by the Contractor. In the construction and maintenance of the camps and services, the Contractor shall ensure that the camp and the buildings which form part of it are kept in good hygienic condition. 3) The Contractor (including its sub-contractor) shall provide alternative fuel arrangement i.e. cooking gas/kerosene oil, electricity free of cost to all its canteen /mess, labourers and staff working in the Project during the whole period of construction activity to avoid felling of trees for use as firewood. In case alternative fuel supply i.e. kerosene, gas, electricity is not available in the project area, the Contractor shall approach the forest department/ forest corporation to open fuel depot in the project area for meeting the demand for fuel wood. 4) The Contractor shall provide, maintain, and remove on completion adequate sanitary facilities to the approval of the Engineer. The Contractor shall prevent pollution of the water supply and shall not discharge sewage which has not been properly treated into natural streams/water courses etc. 5) The Contractor shall make arrangements for treatment on the Site of casualties and sick persons in first-aid units or in such other wards as may be necessary in accordance with the appropriate Regulations. The Contractor shall provide and maintain adequately equipped first aid stations at each of the main working areas. 6) The Contractor shall construct, equip and administer at his cost fire points in such
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positions and of such size as will provide an adequate service for the protection against fire of all buildings, stores and property on the Site. 109 Communications
1) The Contractor shall provide telephone, and radio-telephone facilities as are necessary to permit communication between the various Sites and the offices of the Contractor. 110 Waste Disposal
1) For the disposal of all waste, the Contractor shall designate a suitably located tip which shall be subject to the prior approval of the Engineer. The Contractor shall transport all waste to the tip and then incinerate and immediately bury it. 111 Materials on and under the Site
1) Materials arising from clearance of the Site, soil stripping and excavations shall not be removed from the Site except as required by the Contract. 112 Boundaries Cut Through
1) Fences, walls, etc. crossed by the Works and forming boundaries of plots outside the area occupied by the Works shall not be cut through or destroyed for more than the distance necessary to permit the erection of new fencing etc. and the Contractor shall make the ends of the cut fences secure. Where fences or walls are damaged or destroyed, the whole shall be restored and reinstated with like materials to the satisfaction of the owners, occupiers and the Engineer. 113 Drains, Streams Watercourses etc
1) Drains, pipes, canals, channels, water courses or streams affected by the Contractor's operations shall be reinstated to their original condition. The Contractor shall notify the Engineer in writing 14 days in advance of his intention to start any part of the Works affecting watercourses, canals, streams, drains, pipes, channels etc. The Contractor shall be responsible for maintaining the watercourses within the Site in effective working condition. The Contractor shall take all practicable measures (which shall be subject to the prior approval of the Engineer) to prevent the deposition of silt or other materials in such watercourses etc from his operations. 114 Compensation Water and Flow Past Structure
1) The Contractor shall ensure that during the construction of weir and other structures across rivers and existing channels and up to the time of completion of the relevant parts of the Works, the whole flow of the rivers or channels shall be allowed to pass the Works except for such quantity as the Contractor may reasonably require for the execution of the Works, unless otherwise directed by the Engineer. 2) After completion of those parts of the Works or Temporary Works which form a barrier to river or channel, the Contractor will be required by the Engineer to pass such quantities of water into the river or channel downstream of the structures as may be directed. The Contractor shall not alter the rate of flow of such water except Page 4
with the approval of the Engineer. 115 Keeping Works Free from Water
1) Except where underwater construction is required, the Contractor shall execute all work in the dry, and shall construct any temporary diversion works, drains, pumping systems, and other works that may be necessary for the purpose. The Contractor shall be responsible for the design of these temporary diversion works. 116 Slips
1) The Contractor shall make good any damage or defect caused by slips to any cuttings, excavations or embankments on the site and shall do all necessary work to prevent or remedy the same. 117 Protection of Completed Work
1) The Contractor shall protect completed work from damage during subsequent operations, from the weather or any other cause, including the naturally aggressive nature of the environment in which the Works are to be constructed and make good any damage so arising. 118 Traffic
1) Prior to commencing any work in or which may affect the use of any highway, the Contractor shall obtain the written approval of his proposed methods of working and traffic management plan from the Engineer and the Highway and the Police Authorities. Throughout the duration of the Contract, the Contractor shall cooperate with the Highway and Police Authorities concerning works in, or access to, the highway. Any requirements of such Authorities shall be notified in writing by the Contractor to the Engineer. 2) Where required, the Contractor shall provide and maintain all necessary temporary diversions which shall be operational before interference with existing carriageways, footways or public right of way. The Contractor shall remove all temporary diversions and reinstate the original carriageway as soon as they are no longer required 119 Damage to Access Roads
1) The Contractor shall ensure that damage to any public or private roads, footpaths and tracks used by any vehicles or plant proceeding to or from the Site is kept to a minimum and he shall be responsible for the cost of all repairs necessary to restore such roads, tracks or footpaths to the satisfaction of the Engineer and the owner and/or controlling authorities. 120 Setting Out
1) The Contractor shall set out the Works according to the lines and levels shown on the Drawings. . The coordinates and levels of the primary survey stations are given in Appendix A to this Specification.
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2) The Contractor is to protect all survey stations and benchmarks from disturbance or damage. Any stations or benchmarks that must be removed for construction of the Works shall first be transferred to replacement points 121 Surface and River Bed Levels
1) Before commencing work on any section of the Works, the Contractor shall survey and level the original ground surface and river-bed and shall prepare and submit to the Engineer plans and sections for agreement. 2) At the commencement of the works the Contractor shall carry out a survey to check the levels and co-ordinates of the primary benchmarks relative to each other. 122 Testing Laboratory
1) The Contractor will establish and maintain throughout the period of construction a site laboratory. The laboratory shall be equipped to undertake all the tests on soil and concrete required by the Specification. For other tests, the Contractor may utilise facilities elsewhere in an approved laboratory which must be open for inspection by the Engineer. 2) The Contractor shall, at his own cost, provide moulds, thermometer, slump testing equipment, labour, etc for the sampling of fresh concrete and the preparation and storage of test samples. The Contractor shall deliver the samples together with the sampling records to the laboratory 24 hours before the due date for testing. 123 Safety of Personnel
1) The Contractor shall be responsible for the safety of all personnel on the Site and shall provide his employees and his sub-contractors employees working on the Site and all visitors to the Site with safety equipment appropriate to the tasks upon which they are engaged, such as helmets, safety footwear, gloves, lamps, waterproof clothing, dust masks and safety belts. The use of such safety equipment shall be compulsory as deemed necessary by the Engineer. 2) The Contractor shall provide all lighting and ventilation necessary to ensure a safe and healthy environment for personnel in cases when personnel are working at night, or in enclosed spaces. 124 Protection of the Environment
1) The Contractor shall take all precautions for safeguarding the environment during the course of the construction of the works. He shall abide by the laws, rules and regulations in force governing pollution and environmental protection that are applicable in the area where the works are situated. 2) The Contractor shall obtain materials from quarries or borrow pits only after the consent of the Forest Department or other concerned authorities is obtained. The quarry operations shall be undertaken within the rules and regulations in force. Page 6
3) The Contractor shall ensure that appropriate procedures are complied with for control of any materials used in the Works which are hazardous to the health of persons, animals or vegetation. The procedures shall include, but not be limited to:

Spill containment & clear up Segregation and Storage Selection of low-impact materials where practicable. Provision of protective clothing & equipment for workers handling hazardous materials.
4) The Contractor must take all reasonable steps to minimize nuisance from dust, noise, or other cause during the Construction of the works. Roads in frequent use with heavy traffic shall be watered daily or more frequently if necessary to control dust. The Contractor's attention is drawn to the damage to crops which may be caused by dust. The Contractor is to take such measures as may be necessary to prevent such damage by dust arising from the execution of the Contract. 5) All public roads used by the Contractor or any of his sub-contractors or suppliers of materials or plant, shall be kept clean and clear of all dust/mud or other extraneous materials dropped by the vehicles or arising from the Works. 6) Clearance shall be effected immediately by manual sweeping and removal of debris, or, of so directed by the Engineer, by mechanical sweeping and clearing equipment, and all dust, mud and other debris shall be removed entirely from the road surface. Additionally, if so directed by the Engineer, the road surface shall be hosed or watered using suitable equipment. 7) The Contractor shall observe all agreements entered into by the Employer with any person or persons relating to occupation of the properties by the Employer and to the execution of the Works thereon. The Contractor will be given on request copies of any agreement or part thereof relating to such matters. 8) Compliance with the foregoing does not relieve the Contractor of any responsibility for complying with the requirements of any Highway Authority in respect of the roads used by him. 125 Interference with Existing Works
1) The Contractor shall not interfere in any way with any existing works whether the property of the Employer or of a third party and whether the position of such works is indicated to the Contractor by the Engineer or not, except where such interference is specifically described as part of the Works either in the Contract or in the Engineer's instructions. 126 Photographs
1) Progress colour photographs shall be taken at such times and of such portions of the Works as the Engineer may require. The Contractor shall supply five unmounted copies of each photograph of an overall size of 250 mm x 200 mm. Each copy shall have its Page 7
title, date and serial number printed in black on a 25 mm wide white margin along the bottom edge. The negatives or digital files of the photographs shall be the property of the Employer and no prints from these may be supplied to any person or persons except with the written authority of the Engineer.
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PART 2: WORKMANSHIP AND MATERIALS

201 Workmanship and Materials in General
1) All workmanship shall be of the best quality appropriate to each category of work. Except where otherwise stated or approved by the Engineer, all materials used in the Works shall be of the best quality of their respective kinds as specified or described in the Specification, Drawings and Bills of Quantities and shall comply wherever possible with the current issue of the appropriate standard published by the Indian Standards Institution, or other equivalent national standard proposed by the Contractor and approved by the Engineer. 2) Reference to Indian Standard Specifications or Codes of Practice in the Specification or Bills of Quantities does not imply any bias in favour of equipment, fittings, finishing etc. but is intended to indicate the standard acceptable to the Engineer. The Contractor may relate his offer to other National Standards or Codes of Practice but shall explain the system used and provide the Engineer with all the necessary information and comparisons in English showing that his proposed standards are equivalent to the specified Indian Standards or Codes of Practice. Six copies of such alternative standards in English are to be supplied by the Contractor to the Engineer when required. 3) In all cases where the name of a particular type or make of plant or item is referred to on the Drawings or elsewhere in this Specification, this is intended to indicate only the acceptable standard.
4) The Contractor may offer alternative plant or materials to that specified and in all such cases the Contractor's offer shall be at least of equal quality. When alternatives are offered the Contractor shall submit to the Engineer for approval, a statement detailing the alternatives, and shall include full technical descriptions, drawings and specifications, and shall provide such full information as is required to enable the Contractor to demonstrate to the Engineer that the alternative is equivalent to the item specified. Any further information that the Engineer may require shall be produced by the Contractor when called for. 5) The Contractor shall use locally produced materials in preference to imported materials provided that they comply with the Specification and are available in sufficient and timely quantities. 202 Inspection of Materials
1) The Engineer may employ an inspecting Engineer to inspect materials for the Works at the suppliers' premises or elsewhere, and in this capacity the inspecting Engineer will be regarded as the Engineer's Representative with the limitation imposed by Clause 3 of the Conditions of Contract. 2) Whenever work is to be done at a time when work is not usually in progress, or whenever the regular period for carrying on such work is changed, the Engineer shall be given notice in sufficient time to arrange for proper inspection.
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3) If required by the Engineer, the Contractor shall supply copies of orders placed by him for materials to be incorporated in the Permanent Works so that inspection of the relevant materials can be arranged in sufficient time if considered necessary by the Engineer. 203 Tolerances
1) All works shall be constructed to the tolerances shown in the Appendix B of this Specification.
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PART 3: EXCAVATION AND EARTHWORKS

301 Definition of Earthworks Material
1) The following definitions of earthworks materials shall apply to this and other Clauses of the Specifications in which reference is made to the defined materials: a) top soil shall mean the top layer of soil that can support vegetation; b) suitable material shall comprise all that material which arises from excavations within the Sites and which is approved by the Engineer as acceptable for use in the Works; c) unsuitable material shall mean other than suitable material and shall comprise: i) material from swamps, marshes and bogs; ii) peat, logs, stumps and perishable materials; iii) material susceptible to spontaneous combustion; iv) clay of liquid limit exceeding 90 and/or plasticity index exceeding 65; d) Common material shall mean all material other than that defined as rock hereunder; e) Rock shall mean those geological strata or deposits as described in the Contract, and any material requiring the use of blasting or approved pneumatic tools for its removal, but excluding individual masses less than 1.0 cu.m. 302 Site Clearance
1) The Contractor shall clear the Site as required by demolishing and removing vegetation, debris, buildings etc and the like to approved locations as directed by the Engineer. No access shall be permitted, or damage caused outside the area of the Site. 2) As far as possible, trees greater then 150mm diameter shall be preserved, and no tree greater than 150mm diameter shall be felled without prior approval of the Engineer. 3) Trunks, branches and stumps of trees shall be cleaned of limbs and roots and stacked. Also boulders, stones and other materials suitable for re-use in the Works shall be neatly stacked as directed by the Engineer. 4) Stumps and major roots shall be grubbed up and all combustible material arising shall be gathered into windrows and burnt. The Contractor shall take precautions to prevent the spread of fire to adjacent land. 303 Excavation General
1) Excavation shall be carried out to the lines, levels and profiles shown on the Drawings or to such other lines, levels and profiles as the Engineer may direct or approve in writing. The work shall be carried out by the Contractor in such a way as to avoid disturbance to the surrounding ground. Particular care shall be taken to maintain stability when excavating in close proximity to existing works or natural slopes. 2) The work shall be carried out in a careful manner to ensure that the exposed surfaces
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are as sound as the nature of the material permits and that no point shall protrude inside the lines shown on the Drawings except as otherwise specified or agreed by the Engineer. In soft excavation which is to remain open permanently, exposed faces shall be formed accurately to the required slopes and profiles. Excavations in rock which remain open permanently shall be so trimmed that no point protrudes within the required profile. 3) The Contractor shall dispose of all material arising from excavations. If it is suitable and required for the Permanent Works it shall be placed directly in such Works or set aside for use as and when required in suitable approved stockpiles, otherwise it shall be disposed of in designated spoil areas. 4) The Contractor shall be responsible for keeping all excavations free from water from whatever cause arising, and shall provide such pumping capacity and other measures as may be necessary for this purpose. 5) The Contractor shall properly support the sides of temporary excavations and shall be responsible for their safety. 6) Slope support and slope protection to cut slopes that are to be permanently exposed shall be installed as directed or approved by the Engineer as excavation proceeds. 7) The Contractor shall notify the Engineer without delay of any permeable strata, fissures or unusual ground encountered during excavation. 8) Where blasting is required the blasting to final profiles shall be carried out using presplitting techniques. 304 Excavation Beyond True Lines and Levels
1) If from any cause whatsoever excavations are carried out beyond their true line and level, the Contractor shall make good to the required line and level with the appropriate grade of filling to be contained in the true excavation, or with concrete or other approved material in such a manner as the Engineer may direct. 305 Approval of Excavations
1) When excavations have been taken out accurately to the profiles or dimensions required for the work, the Contractor shall inform the Engineer so that he may carry out an inspection. 2) If, after inspection, the Engineer requires additional excavation to be carried out, the Contractor shall do so to such new profiles or dimensions as the Engineer may direct. 3) The Contractor shall obtain approval of excavations prior to placing pavement layers, fill or concrete. 4) The Contractor shall maintain open excavations in an approved condition, and shall rectify the effects of deterioration due to weather.
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306
Excavations for Structures
1) Open excavation to form foundations for a structure shall be carried out to the lines necessary to permit the proper construction of the structure or as directed by the Engineer. 2) If required, before any concrete for a foundation is placed, the bottom of the excavation shall be re-compacted to achieve at least 95% of the maximum dry density determined in accordance with (IS 2720 ( part 18). 3) The Contractor shall carry out the excavation in a safe manner such that the sides of the excavation are adequately supported and stable. 4) The excavation shall be excavated and supported by methods which will not endanger the stability of the surrounding slopes or works. 307 Disposal of Surplus Excavated Materials
1) Available spoil areas are to be used for disposal of surplus excavated materials.. If additional areas are required, the Contractor shall be responsible for obtaining the necessary approvals from the owners and the local authorities. 2) The Contractor shall organise and carry out the placing of spoil in such a way that the natural drainage to existing waterways is not impeded. Contamination of existing waterways shall be avoided and suitable drainage shall be provided, if necessary. 3) Spoil material shall be placed in the spoil areas to form stable, free-draining banks. 4) The Contractor shall submit to the Engineer for approval all necessary data showing mucking areas, working methods and drainage and stabilizing provisions before placing of spoil in any areas. Excavation by Blasting 308 Procurement, Storage and Handling of Explosives
1) The Contractor will obtain the necessary licences for purchase and storage of explosives and detonators and shall be responsible for the acquisition, transport, custody and storage of explosives. 2) The Contractor shall submit to the Engineer his proposals for the use of explosives in connection with the Works and the programme for their procurement and transport to site. . 3) The Contractor shall be responsible for the quality and satisfactory performance of explosives. 4) Only such quantities of explosives and sundries as are required for the working day shall be released from the magazine and the Contractor shall not store additional explosives and ancillary components elsewhere. Any unused materials shall be
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returned to the magazine and recorded accordingly. 309 Magazines
1) The Contractor will establish, operate and maintain the magazine for the storage of his explosives. 310 Blasting
1) When blasting is permitted, it shall be carried out only after the Contractor has provided adequate visible and audible warning systems, safety men and all such measures as are necessary to prevent injury to persons and property and protect the Works from damage during blasting, and shall be carried out with the greatest care, strictly according to the arrangements approved by the appropriate Authority. 2) The Contractor may choose his own methods for drilling and blasting rock subject to the approval of the Engineer. 3) Only workmen who are in possession of a blasting certificate valid for the type of blasting to be carried out shall be permitted to be in charge of blasting operations. 4) All charging of drill holes, type of detonation, etc, shall be in accordance with modern methods and recognised good practice. 5) If the prevalence of electrical storms makes it unsafe to use electrical firing in blasting operations the Contractor shall use an alternative type of firing. 6) The Contractor shall take all necessary precautions with respect to the use of electrical detonators in the vicinity of static and mobile radio transmitters including normal radio and television broadcasting stations and radar units associated with aircraft movements. 7) A register of all explosives used, firing amounts and location shall be maintained by the Contractor and be available at all times to the Engineer for checking. 8) The use of explosives will not normally be permitted within 15m of any structure or part of a structure. Where permission to use explosives is withheld, the Contractor will not be entitled to any additional payment in respect of alternative methods necessary for carrying out the work. 9) When blasting within 15m of a structure(s) is permitted it shall be carried out by small charges and /or milli-second delay fuses in such a manner as to reduce the level of vibration occurring which the Engineer may require to measure. Care shall be taken that blasting does not open fissures in the rock or overburden under or adjacent to parts of the Works. 10) Where blasting is proposed adjacent to a building or other structures existing or under construction, the Contractor shall satisfy the Engineer that safe values of vibrational amplitude and peak particle velocity will not be exceeded.
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11) Where required by the Engineer, the Contractor shall employ heavy mesh blasting nets or other approved means to limit the scatter of debris and flying particles. 12) Blasting shall be restricted to such periods as the Engineer may prescribe. 311 Underground Excavations
1) The method and procedures for excavation in tunnel by tunnelling methods covered under these specifications shall conform to latest revisions of the following Indian Standards specifications or any International recognised standards. IS 4756 IS 5878 Safety code for tunnelling work Code of Practice for construction of tunnels conveying water: (Part - I Precision Survey and Setting Out). Code of Practice for Construction of Tunnel conveying water: (Part 2 - Underground Excavation in Rock) Section I Drilling & Blasting Code of Practice for construction of tunnels conveying water. (Part 2 - Underground excavation in rock) Section 2- Ventilating, lighting, mucking and dewatering. Code of Practice for construction of tunnels conveying water. (Part 2 - Underground excavation in rock) Section 3- Tunnelling method for steeply inclined tunnels, shafts and underground power houses Code of Practice for construction of tunnels conveying water: (Part -3 Underground excavation in soft strata) Code of Practice for construction of tunnels conveying water: (Part - 4 Tunnel Supports) General requirements for blast hole drilling rigs
IS-5878
IS 5878
IS 5878
IS 5878
IS 5878
IS 7209
2) The Clearance Line is shown on the drawings. It defines the minimum dimensions of the clear opening which is obtained after excavation and installation of any required support system. The ends of rockbolts may be permitted to protrude inside the Clearance Line where concrete linings are provided. Otherwise, no projection will be permitted within the Clearance Line without the written consent of the Engineer. 3) The quantity of excavation to be measured and paid for at the unit rate will be the quantity included within the Clearance Line plus the thickness of any permanent support system.
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4) The drilling pattern shall be such as to minimize over excavation, and also to cause least disturbance to or shattering of surrounding rock mass. The drilling pattern shall be adjusted to suit the geological conditions of rock strata. 5) Blasting shall be controlled and conducted in such a manner, not to endanger any adjacent property or structures and as not to affect or hinder the progress of adjoining works. The type of explosives to be used and the quantity of charge shall be adjusted to suit the geological conditions of rock strata. The rules in force for handling, transporting and storing explosives (as laid down in the Indian Explosives Act or any other Act having the force of law) shall be strictly adhered to. 6) After blasting, the whole surface of excavation shall be carefully examined and all loose rock and projections etc., removed in such a way that there shall not be any danger of any piece of rock falling down subsequently; due to any cause whatsoever. After the section is excavated, it shall be carefully trimmed to remove any projections that may be found within the profile defined by the Clearance Line. Geological mapping of the faces shall be prepared by the Contractor for every round of blasting operation. 7) The whole excavated reach of the Tunnel shall be properly ventilated, either by artificial means or by natural draft. The Contractor shall provide at his own cost, ventilation fans of adequate capacity and ducts of suitable size to force in air into the tunnel during working hours. The fans shall be of the reversible type so that the gases released after blasting shall be sucked out of the tunnel in the shortest possible time. 8) The workmen shall not be allowed to enter and start work unless and until all the objectionable gases are removed to the extent considered safe and satisfactory. 9) The capacity of the ventilation plant shall be adequate to allow the removal of blast gases within as short a time as possible to allow starting of mucking operations commensurate with the schedule of progress of work. 10) The entire length of Tunnel excavated shall be adequately illuminated by electric lights in accordance with IS: 5878-Part-2-Section-2. The working face and the working area shall be brightly illuminated either by adequate floodlights or by other means. The facility of lights in the tunnel shall also be made available for the use of inspecting officers and any visitors, if required, during non-working hours, at no extra cost. In addition every workman, working inside the tunnel shall have a battery operated torch either fixed to the helmet or hand held. 312 Rockbolting
1) This specification covers supply and installation of rock bolts and associated works conforming to I.S.1570 (PART-1):1978 or latest edition. 2) Rock bolts shall be 25mm diameter mild steel deformed bar threaded at one end as shown in the drawings. The length of the rock bolts and pattern in which the rock bolts shall be installed shall be as shown in the drawings or as otherwise prescribed Page 16
by the Engineer. Rock bolts shall have a tensile strength of 410 MPa and minimum yield strength of 250 MPa and minimum elongation of 23 percent and they shall be threaded. All nuts for the rock bolts shall be heavy duty hexagonal, double chamfered confirming to black hexagon bolts, nuts and lock nuts and black hexagon screw IS 1363-1967 or the subsequent revision. 3) Bearing plates shall be flat steel square plates 150 mm X 150 mm X 10 mm and conforming to Structural steel (standard quality) IS 2062:1992 or its subsequent revision. For the purpose of grouting the flat steel bearing plates shall have separate holes for the grout tubes. 4) Cement for grout shall be ordinary Portland cement confirming to Ordinary and low heat Portland cement IS8112-1989 or its subsequent revision. The average fineness value of the cement shall not be less than 4,500 square centimetres per gram. 5) Rock bolts shall be installed as soon as possible after each blasting. The Contractor shall be well prepared to perform such work and the equipment used for that work shall allow the Contractor to insert the rock bolts up to the face with the necessary speed and accuracy and if possible, without removing the recently excavated material to install them. Any rock bolts that are affected by subsequent blasting shall be replaced by new rock bolts installed nearby. 6) The diameter and depths of drilled holes and the method of cleaning the same for rock bolts shall be such as will promote effective anchoring and grouting of the rock bolts and ensure that the inner end of the rock bolts does not protrude beyond the Clearance Line by more than 70mm. 7) Once the drilling is completed, the bore holes shall be cleaned by means of water and air under pressure in order to remove small particles of rock or dust remaining in it, so that the hole is perfectly cleaned before the insertion of the rock bolt. 8) Holes for rock bolts shall generally be drilled normal to the Clearance Line unless otherwise shown on the drawings or ordered by the Engineer. The actual position of the rock bolts shall be chosen such that the shank is not bent or stressed due to excessive inclination between the rock face and the shank. The direction of bolts shall be modified to suit the rock jointing pattern as observed at site on excavation as per the instructions of the Engineer and rock bolt spacing shall be adjusted locally to suit the joint spacing and pattern. 9) In general, cement capsule anchors shall be used. Where separate grouting is approved by the Engineer, bolts shall have the grouting tube attached. The Contractor shall supply plastic piping in rolls which shall be cut and attached to the bolts with adhesive tape or another approved method. .
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10) Grout for rockbolting shall be made up of portland cement and water with a watercement ratio of approximately 0.4 by weight to which aluminium powder shall be added if required in a proportion indicated by the engineer. 11) Unless otherwise directed or approved commercial grade extra fine aluminium powder in an amount not exceeding 0.005 % by mass of cement shall be blended with the cement to ensure the necessary expansion of grout. 12) Grouting shall be applied at a moderated pressure (2kg/cm2) unless indicated otherwise until the voids between the bolts and the rock are completely filled. As soon as the grouting is finished, the grouting holes shall be plugged to avoid leakage of grout. 313 Steel Rib Supports
1) The Contractor shall maintain a minimum stock of 10 (ten) complete ribs and their associated fittings at Site to allow immediate installation in cases where unstable rock conditions are encountered. 2) The method and procedures for providing and fixing steel ribs covered under these specifications shall conform to latest revisions of the following Indian Standard Specifications or any International recognised standards. IS 800 IS 808 Code of Practice for general construction in steel. Dimensions for hot rolled steel beams, column, and channel and angle section. Specification for Weld able Structural Steel. Safety code for tunnelling work. Code of practice for design of tunnels conveying water(Part-VI) Tunnel Supports. Code of Practice for construction of tunnels conveying water (Part IV) Tunnel Supports.
IS 2062 IS 4756 IS 4880
IS 5878
3) Ribs shall be placed such that the inner face is not inside the Clearance Line. Any extra excavation necessary for placing these supports shall be paid for at the same rate as the main excavation. The exact type, design and extent of permanent supports, required in the tunnel shall be proposed by the Contractor based on the condition of rock and the likely rock loads and subject to approval by the Engineer.. The rib support system shall include anchoring if required, lagging, supporting, wedging, etc. to ensure proper supporting of excavated surface.
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314
Shotcreting
1) All methods and procedures for providing and installing shotcrete and wire mesh reinforcement shall conform to Indian Standard specifications and other publications listed below unless otherwise specified. Indian Standards IS 8112 - 1989 Specification for 43 grade ordinary Portland cement. (First Revision). IS1566-1982 Specification for Hand Drawn Steel wire fabric for concrete reinforcement. IS 1570 (Part-I): 1978 Steel specified by Tensile and/or yield properties. IS 9012- 1978 Recommended practice for shotcreting/ latest publication, if any. 2) Water to be used for shotcreting shall confirm to requirement given in IS 456: 1978. 3) Sand for shotcrete shall comply with the requirements given in IS : 383:1970 and graded evenly from fine to coarse as per Zone II and Zone III grading of IS 383:1970. 4) Coarse aggregates shall comply with the requirements of IS: 383-1970. It shall, generally confirm to one of the grading given below. The maximum size of coarse aggregate to be used shall be restricted to 12.5 mm. Grading of Coarse Aggregates IS Sieve Designation (mm) 25 20 12.5 10 4.75 2.36 1.18 Percentage by Mass Passing for Aggregate of Nominal Maximum Size 10 mm 12.5 mm 100 100 90-100 85-100 40-70 10-30 0-15 0-10 0-5 0-5 -
All oversize pieces shall be rejected by screening, since they are likely to cause blockages in the equipment. 5) Admixtures shall be in accordance with the requirements of IS 9103 : 1979 and as approved by the Engineer. The proportion of admixture (as a percentage of cement)
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shall be approved by the Engineer. Admixtures containing chlorides will not be permitted. 6) Batching and Mixing The ingredients of the mix for shotcrete and strength criteria shall be as follows i) Aggregates shall be well graded to achieve good pumpability through the spraying nozzle and the maximum size of coarse aggregate shall be limited to 12.5 mm, generally the mix design shall constitute one part of cement, one part of sand (fineness modules of 2.4 and above) and two parts of well graded aggregate however the mix proportions may vary as required by the Engineer. ii) Shotcrete mix design shall ensure 28 day characteristic compressive strength of over 25 MPa (25 N/mm2). iii) Water cement ratio for shotcrete in place shall be in the range of 0.35 to 0.40 by mass. The water content of the mix shall be limited to prevent sloughing. iv) The rate of gain of strength of shotcrete shall conform to the following compressive strength requirements. Age 1 hour 2 hours 8 hours 12 hours 24 hours 72 hours 7 days 28 days Compressive Strength of Shotcrete (MPa) 0.2 0.50 0.75 4.00 4.50 5.00 10.00 11.00 12.00 12.50 17.00 17.50 > 25
v) The cement to be used for shotcrete shall be weighed first before mixing with the coarse and fine aggregate. Every batch of concrete for shotcrete shall be prepared for 50 Kgs of cement or whole multiple thereof. The Contractor shall use weighing equipment to the accuracy of 0.1 kg to measure weight of cement added in each batch. vi) Mixed dry aggregate and cement, which do not contain a set accelerating admixture and which are not placed with in 30 minutes after mixing, shall be discarded. Mixed dry ingredients, which contain a set accelerating admixture shall be discarded if they are not placed within the time as determined by the
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Engineer depending on the moisture content of the mix and the amount of admixture. vii) Mix proportions shall be adjusted as necessary to obtain the required strength of shotcrete and to keep rebound to the minimum. 7) Air and water shall be provided in such volume and under such pressure as may be necessary for the best operating conditions. In applying shotcrete, the discharge nozzle shall be held in such a way that the stream of material shall impinge as nearly as possible at the optimum angle to the surface for minimum rebound, and the velocity of the discharge from the nozzle. The distance of the nozzle from the surface and the amount of water used in the mix shall be regulated so as to produce a coating with a minimum rebound of the material, with no sagging. Obstructions, such as service lines, shall be removed to enable direct application of shotcrete to the surfaces. Rebound material shall not be used again, but shall be removed from the work and disposed of by the Contractor. During application of shotcrete the Contractor shall provide adequate ventilation facilities and take such other measures as are necessary for safety of his workmen including provision of face protection for nozzle men. 8) The locations where shotcrete is to be used shall be as shown on the drawings or as directed by the Engineer. Where shotcrete is to be applied, the Contractor shall clean and prepare the surface by removing loose or shattered rock, rock debris, clay or other loose materials. The surface shall be washed, where required, with a strong air and water jet or by other means approved by the Engineer. 9) Nozzle men shall have had sufficient previous experience in the application of coarse aggregate shotcrete or shall work under the immediate supervision of a foreman or instructor having such experience. 10) Alkali hydroxides and other chemicals contained in shotcrete admixtures are moderately toxic and can cause skin and respiratory irritation unless adequate safety measures are taken. In applying shotcrete containing toxic admixtures, the nozzle men and helpers shall wear appropriate hoods to protect them against toxic or objectionable material. 11) Gloves and necessary protective clothing shall be worn to protect against dermatitis. 315 Fill
1) Material for filling shall be obtained from approved sources or selected from excavations containing no vegetable or perishable matter, graded to ensure a dense stable and homogeneous fill when compacted. 2) Fill shall be placed in layers not exceeding 250mm thickness, each layer being
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scarified and thoroughly compacted by four passes of a vibratory steel drum roller with a static drum weight of at least 7 tonnes. Unless otherwise specified, compaction shall be not less than 90% of the laboratory maximum dry density as determined in accordance with IS 2720 (part 18). 3) In places where space restriction prevents the use of compaction equipment mentioned above, the compaction shall be carried out by means of approved small size equipment. If necessary the thickness of layers shall be adjusted in order to achieve the same degree of compaction as with normal equipment 4) The fill material prior to compaction shall be brought to a moisture content within the range 2% of optimum. If watering is required it shall be carried out in such a manner as to ensure the even distribution of water throughout the layer to be compacted and the compaction operations will follow whilst the moisture content remains within the specified range. 5) The Contractor shall take all necessary measures to prevent any damage or defects to the Works which may be caused by settlements, slips or falls of embankments and shall make good such damage or defects as may occur, to the satisfaction of the Engineer. 6) Any instability of any adjacent excavation or slopes resulting from the embankment not being formed to the lines, levels and profile shown in the drawings or as ordered by the Engineer will be the responsibility of the Contractor. 7) All fill materials shall be handled in such a way that they are un-segregated once they are in their final positions. 316 Backfill to Structures
1) Backfill shall generally be selected material from excavation, approved by the Engineer. 2) Material shall be moisture conditioned and then compacted to provide not less than 95% of the laboratory maximum dry density as determined in accordance with IS 2720 (part 18). 3) The Contractors proposed method of working for compaction around structures shall be subject to prior approval by the Engineer.
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PART 4: CONCRETE
401 Cement
1) Cement shall generally be Pozzolana Portland Cement (or Ordinary Portland Cement as an alternative). . 2) Cement procured by the Contractor in sealed bags, marked with manufacturers name, shall be delivered to the Contractors storage facility and shall be protected from the weather by approved coverings. Damp bags shall be rejected. 3) The Contractor shall ensure that the arrangements for the storage of the cement on the Site as hereinafter specified are sufficient for the segregation and identification of each consignment. 4) No cement shall be used in the Works until it has been passed as satisfactory by the Engineer. 5) Where designated by the Engineer, fly ash (Pulverised fuel ash) conforming to Grade-1 of IS:3812 may be used as a part replacement of ordinary portland cement provided uniform blending with cement is ensured and that the design mix gives required strength to concrete within the required period. 402 Storage of Cement
1) While being unloaded and during transit to the concrete mixers, whether conveyed in vehicles or by mechanical means, the cement must be protected from the weather by effective coverings. 2) Cement in bags shall be stored in weatherproof and well-ventilated sheds. On delivery at the Site the cement is at once to be placed in these sheds and shall be used in the order in which it has been delivered. 3) The Contractor shall be responsible for damage to cement bags while unloading and transporting around the Site and in no case shall cement from a damaged bag or hardened lumps be used in any of the Permanent Work. 403 Fine Aggregate
1) Fine aggregate for concrete shall be clean sand complying with (IS 2386 part 1 to part 8). The sand shall be from approved sources and sand which, in the opinion of the Engineer, is not clean shall be washed before use. 2) The fine aggregate shall be free from salt, alkali, calcium sulphate or vegetable matter. It shall not contain more than 0.5 percent by weight of clay lumps. 3) Fine aggregate shall be capable of passing through a 5mm test sieve and shall be graded so that when mixed with the coarse aggregate and cement a concrete of maximum density is produced. It shall not contain appreciable amounts of flaky or elongated particles.
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4) The grading of fine aggregate shall comply with one of the Coarse, Medium or Fine classifications as given below. In the event that the grading of the sand changes to a different classification from that used when concrete mixes were designed and approved, new trial mixes shall be carried out. Sieve size Percentage by mass passing IS sieve Overall Additional limits for grading Limits Coarse Medium Fine 100 89 to 100 60 to 80 30 to 100 15 to 100 5 to 70 0 to 15 60 to 100 30 to 90 15 to 54 5 to 40 65 to 100 45 to 100 25 to 80 5 to 48 80 to 100 70 to 100 55 to 100 5 to 70
10.00 mm 5.00 mm 2.36 mm 1.18 mm 600 m 300 m 150 m
5) Crushed sand may be added to natural sand in approved proportions in order to achieve the required grading. Crushed sand alone may not be used without approval. The amount of material passing a 75 micron sieve shall not exceed 3% by weight. 6) When subject to five cycles of the soundness test specified in IS 1607 : 1977, fine aggregate shall show a loss not exceeding 10% when magnesium sulphate solution is used. 7) Sand for mortar shall comply with IS 2386 Part 1 to Part 5. 404 Coarse Aggregate
1) Coarse aggregate for concrete and other purposes shall comply with (IS 2386 part 1 to part 8). It may be either natural gravel or stone broken to the desired size and shall be obtained from quarries, pits or other sources approved by the Engineer. 2) Gravel or ballast shall be free from clay, earth, loam or other organic or similar material and shall be approved by the Engineer. Any sand in the bulk gravel shall, unless otherwise directed, be removed by screening and if required kept apart. The sand thus obtained may be used in concrete provided that in the opinion of the Engineer, it complies with the specifications for sand in the preceding Clause. Gravel or ballast which, in the opinion of the Engineer, is not clean shall be thoroughly washed before use. 3) Broken stone shall be of hard durable rock. Notwithstanding approval by the Engineer of its source, the stone as delivered to the Works will be subject to rejection if for any reason the Engineer considers it unsatisfactory. It must be perfectly clean Page 24
and no soft, clayey, shaley or decomposed stone will be approved. The stone must be broken in a stone crusher of approved type to the sizes hereinafter specified and any dust or fine material below 5 mm in size made in the stone crusher is to be removed by screening if so required and, if the Engineer so orders, the stone shall be thoroughly washed by an approved method. 4) When so required and before construction commences, laboratory tests shall be made of the aggregates to be used on the Works will be undertaken by the Employer to establish their suitability for concrete. In addition to these laboratory tests the Engineer may require check tests of actual deliveries to be made at the Site from time to time. 5) The grading of coarse aggregate shall comply with the appropriate classification as given below. Coarse Aggregate Grading Sieve size mm 50.0 37.5 20.0 14.0 10.0 5.0 2.36 Percentage by mass passing BS sieves for nominal sizes Graded aggregate Single-sized aggregate 40mm 20mm 14mm - 5mm -5mm -5mm 40mm 20mm 14mm 10mm 5mm 100 100 90-100 100 85-100 0-25 0-5 0-70 0-25 0-5 35-70 90-100 25-55 40-80 90-100 10-40 30-60 50-85 0-5 0-10 0-10 85-100 100 0-50 0-10 -
85-100 100
85-100 100 0-25 45-100 0-5 0-30
6) Coarse aggregate shall be graded so that when mixed with the approved fine aggregate and cement, a workable concrete of maximum density is produced. 7) The amount of material passing a 75 micron test sieve shall not exceed 1% by weight. 8) When subjected to five cycles of the soundness test specified in IS 1607, coarse aggregate shall not show a loss exceeding 10% when magnesium sulphate solution is used. 9) The flakiness and elongation indices of the predominant size fractions in each single sized coarse aggregate, determined in accordance with BS 812, shall not exceed 20% and 35% by weight respectively.
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405
Testing of Aggregates
1) Aggregates will be tested in accordance with the following schedule and shall comply with the stated limits Test Frequency Acceptable Limits Coarse Fine aggregate aggregate 4% from the design mix target 10% 2% 1% 1% 0.4% 0.05% 20% 20% 35% twice daily* 10% 2% 3% 3% 0.4% 0.1% n/a n/a 3 times daily*
Grading Magnesium sulphate soundness (ASTM C88) Water absorption Clay, silt and dust content Organic impurities (ASTM C40, C87) Sulphate and Chloride Aggregate crushing value Flakiness and Elongation Moisture content
weekly monthly weekly weekly monthly weekly weekly weekly
* daily during dry season. Mix proportions to be adjusted to compensate for moisture content of aggregates
406
Aggregate Reactivity Potential
1) Aggregate shall not contain any materials that are reactive with alkalis in the aggregate itself or in the cement, the mixing water or in water in contact with the finished concrete or mortar in amounts sufficient to cause excessive localised or general expansion of the concrete mortar. 2) The Contractor shall assess an aggregate source by testing in accordance with IS 2386 Part 1 to Part 8 and the results shall comply with the limits given in the relevant Indian Codes for overall effect on the permanent works mixes, before use of the aggregate is approved. 407 Water
1) Clean fresh water is to be used for the mixing of all concrete and mortar, and is to be from a source approved by the Engineer. Khiraoganga river water free from silt and debris has been determined to be satisfactory. If required by the Engineer, samples shall be taken from any other proposed source of supply and submitted to a nominated laboratory for testing in accordance with IS 3025 (part 17, 18, 24 and 32) and on the results of these tests the Engineer will decide whether the source is acceptable. Page 26
2) The acid soluble sulphate (SO3) content shall not exceed 500 mg/l and the acid soluble chloride as NaCl (Cl x 1.65 = NaCl) content shall not exceed 600 mg/l. Tests to establish the contents shall be carried out at monthly intervals. 408 Admixtures
1) Admixtures shall not be used in concrete without the Engineers approval. Admixtures containing chloride or other corrosive agents shall not be used. 2) Where the mix design utilises admixtures, they shall be used in the correct quantities in accordance with the manufacturers recommendations. Approved equipment and methods shall be used for dispensing and incorporating the admixture in the concrete; the dispensing unit shall be designed so that the discharge of the admixture visible and is automatic in each batch. 3) The concrete tests described herein shall be conducted with the admixture incorporated to establish that specified strengths are achieved, and that densities are not reduced. If air entraining agents are used the density shall not be reduced by more than 5%. 4) Set retarding and water-reducing admixture shall consist of lignosulphonate. Air entraining agents shall consist of neutralised vinsol resin.
409
Concrete Mixes
Concrete shall be as shown below Concrete Grade Characteristic Strength at 28 days N/mm2 40 25 25 20 20 15 10 10 Maximum Aggregate Size mm 20 20 12 20 40 20 20 40 Minimum Quantity of Cement Kg/m3 375 350 350 330 300 240 130 130 Maximum Free Target Water-Cement Slump Ratio mm 0.50 75 0.50 0.50 0.50 0.55 0.60 75 75 75 75 75
M40 M25 M25/12 M20/20 M20/40 M15 M10/20 M10/40
410
Plum Concrete
1) Plums shall be hard clean natural stones embedded in mass concrete, Class M20/40,
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during the placing of the concrete. The plums shall not be larger than one third of the cross section of the concrete, with a maximum size of 300mm and should not be placed closer than 50mm to each other. The volume of plums shall not exceed twenty five per cent (25%) of the mass concrete volume and care shall be taken to ensure that the minimum concrete cover over any plum is 75mm. 411 Concrete Mix Designs
1) Preliminary tests will be carried out by the Contractors laboratory to determine the mixes which will satisfy the Specification with the available materials. These mixes will be designed with due regard for the workability necessary to allow the Contractor to place and compact the concrete with the equipment he proposes to use in any particular situation. 2) The mixes will be designed to have mean strengths that are greater than the specified characteristic cube strengths by a margin of 1.64 times the standard deviation expected from the concreting plant. The standard deviation will be calculated from at least 40 individual cube results each representing separate batches of similar concrete produced by the same plant and under the same supervision except that no standard deviation less than 2.5 N/mm2 shall be used as a basis for designing a mix. A standard deviation of 5N/mm2 shall be used for initial mix design purposes. 412 Trial Mixes
1) Trial mixes shall be prepared under full scale conditions and tested in accordance with (IS 9013 : 1978). Trial mixes shall be made subsequently whenever a change is intended in materials or in the proportions of the materials to be used. Representative samples of the materials to be used shall be taken and three trial mixes using the proposed proportions shall be made on different days. The workability of each of these three mixes shall be determined by measurement of slump and a batch of six cubes from each mix shall be made, three for tests at 7 days and three for tests at 28 days. The Engineer will normally approve the proposed mix proportions provided the average strength of the three trial mixes is not less than the designed mean strength minus the designed standard deviation and subject to the conditions noted below. Further trial mixes shall be made if the range of strength that is the maximum minus the minimum, of the three cube results in any batch exceeds 15% of the average of that batch, or if the range of the three batch averages exceeds 20% of the overall average of the batches. 413 Works Test
1) Test cubes shall be made by the Contractor and cured, stored and transported to the laboratory in accordance with IS 9013: 1978. The cubes shall be tested in compression at the Contractors laboratory. The method of compacting cubes by vibration shall be subject to the approval of the Engineer 2) A sample of concrete shall be taken at random each day of concrete of each grade made. The number of samples per day and the time when they shall be taken shall be varied at random or as directed by the Engineer.
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3) From each sample two cubes shall be made for testing at twenty eight (28) days and one for testing at seven (7) days for control purposes. 414 Test Failure
1) Should any works test cube fail to attain the specified strength, an immediate examination shall be made to find the cause of the failure and a report sent to the Engineer who will take suitable action which may be one of the following:
Order the concrete corresponding to the cubes to be cut out and replaced. The
Engineer shall determine the extent of the concrete at risk.

When the failure, in the opinion of the Engineer, is slight and occurs in a
continuing concreting operation for a large mass of concrete, the next works test result may be awaited and, if the failure then persists, the Engineer may order that concreting shall cease forthwith and not be resumed until further preliminary tests indicate that the mix has been corrected. Otherwise the concreting may be allowed to continue with the same mix.
When the failure is serious and relates to a concrete mass which lends itself to it,
the Engineer may order one or more test cylinders to be drilled out and tested in accordance with (IS 9013: 1978). According to the result of these tests the Engineer may order the suspected concrete to be cut out and replaced. 2) The cost of these tests including the cutting out and replacing of concrete of inferior quality shall be borne by the Contractor if the test results show the concrete not to be in accordance with the Specification. 415 Workability
1) The wet concrete shall be of such consistency that it can be readily transported, placed and compacted in the Works without segregation of the materials. The resulting concrete shall be uniform and free from honey-combing 2) The Contractor shall carry out slump, compaction factor or other workability tests as required during concreting of the permanent works in order to confirm that the degree of workability of the mix complies with the numerical value obtained during the trial mixes 416 Concrete Returns and Records
The Contractor shall send weekly to the Engineer a return showing the quantities of cement and the number of mixings of each class of concrete used in each section of the Works. 1) Records shall be kept by the Contractor of the positions in the Works of all batches of concrete, of their class and of all test cubes or other specimens taken from them. Copies of these records shall be supplied to the Engineer and Contractors laboratory.
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417
Batching and Mixing of Concrete
1) The aggregates and cement shall be proportioned by weight. The weigh batching equipment shall be carefully maintained and cleaned and shall be provided with simple and convenient means of checking the accuracy of the weighing mechanism. The equipment shall be checked when required by the Engineer. 2) The concrete is to be mixed in machines of the batch mixing or other approved type. The machines shall ensure that all the concreting materials including the water are thoroughly mixed together before any portion of the mixture is discharged. The machines must be capable of discharging their contents while running. 418 Concrete Placing
1) Concrete shall be placed in the position and sequence indicated on the Drawings, or as directed. Placing shall not be commenced until the fixing and condition of reinforcement and items to be embedded and the condition of the containing surfaces or formwork has been approved by the Engineer. 2) Concrete shall be transported by means which prevent contamination (by dust, rain etc.) segregation or loss of ingredients, and shall be transported and placed without delay. 3) Concrete shall be placed directly in its final position without segregation or displacement of the reinforcement, embedded items and formwork. Concrete shall not be placed in water, except as specified. Concrete shall not be dropped through a height greater than 1.5 metres. 4) Surfaces of excavations or filling which are to receive reinforced concrete work shall, where indicated, be prepared with a blinding layer of concrete as shown on the drawings or in such other manner as will provide a suitable surface at the correct lines and levels to the satisfaction of the Engineer. Placing of this blinding layer shall be carried out immediately following excavation inspection approval by the Engineer, to prevent any deterioration of the excavated surface. 5) The concreting shall be carried out in such a way that the struck exposed faces of concrete shall be sound and solid, free from honeycombing and excrescences. No plastering of imperfect concrete faces will be allowed in any circumstances. All concrete that is defective in any way will, if so ordered by the Engineer, be cut out and replaced to such depth or be made good in such manner as the Engineer may direct. 6) Where concrete is required to be placed against undisturbed ground, the entire space between the finished concrete surface and the ground, including any overbreak, is to be completely filled with concrete of the specified class. The concrete shall be well rammed and compacted to ensure that all cavities are filled and the concrete is everywhere in contact with the ground. Where permitted by the Engineer, patches of overbreak may first be filled with concrete Class M10/40, as directed, to within 100mm of the payment line.
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419
Concrete Placing Equipment
1) Concrete shall be placed without segregation. If chutes are used their slopes shall not cause segregation and spouts or baffles shall be provided 420 Time for Placing Concrete
1) Concrete and mortar must be placed and compacted within 30 minutes of water being added to the mix or otherwise included via damp aggregates, unless admixtures are in use. Partially set concrete shall not be used in the Works 421 Compaction
1) Concrete shall be compacted during placing by approved internal vibrators. The vibrators shall operate at a frequency of not less than 10,000 cycles per minute, and shall be designed for continuous operation. The performance of vibrators shall suit the working conditions, and they shall generally not be less than 50mm diameter. The radius of influence shall ensure that the mass under treatment is compacted at a speed commensurate with the rate of supply of concrete. 2) Vibrators shall penetrate the full depth of the layer of concrete placed and just into the layer below, and be withdrawn slowly to avoid the formation of voids. 3) Vibration shall not be applied directly or indirectly to concrete after the initial set has taken place, nor shall it be used to make concrete flow in formwork. 422 Placing in Inclement Weather
1) Placing shall not take place in the open during storms or heavy rains. If such conditions are likely to occur, the Contractor shall provide protection for the materials, equipment and formwork so that work may proceed. If strong winds are prevalent, protection from driving rain and dust shall be provided. 423 Placing in High Temperature
1) The temperature of concrete shall not exceed 32oC at the time of placing and the maximum concrete temperature after placing shall not exceed 65oC. 424 Formwork
1) The Contractor shall obtain approval of the methods and materials proposed. Formwork shall provide concrete of the shape, lines and dimensions shown on the Drawings. 2) Formwork shall be constructed from materials of sufficient strength, supported to provide rigidity during placing and compacting concrete without discernible deflection and shall be removable without disturbing the concrete. Metal ties or anchors within the formwork shall be so constructed or sleeved so as to permit either their complete removal or their removal to a depth of at least the minimum specified cover from the face without damage to the concrete. All fittings for removable metal ties shall be of such design that, upon removal, the cavities left are of the smallest possible size. After removal of formwork and tie bars, the holes shall be plugged
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with mortar. 425 Preparation of Formwork
1) Before concrete is placed, the formwork shall be thoroughly cleaned; free from sawdust, shavings, dust or other debris. Temporary openings shall be provided to assist in removal of the rubbish. 2) After cleaning, the formwork shall be coated with an approved release agent, which shall not be allowed to run on to reinforcement, other embedded steelwork or concrete at any construction joint. In general, coating shall be carried out before final assembly of formwork. 3) All formwork shall be inspected and approved in writing by the Engineer before concrete is placed in it, though this shall not relieve the Contractor from the requirements as to soundness, finish and tolerances of the concrete specified elsewhere. 426 Classes of Finish
Formed finishes comprise: 1) Class F1 Finish: Formed surfaces which are not exposed to view and where roughness is not objectionable shall, in general, require no treatment after form removal other than repair of defective concrete and filling of holes left by form ties. 2) Class F2 Finish: All permanently exposed, formed surfaces shall be smooth and dense, free from offsets, abrupt irregularities and other prominent surface blemishes. Unless specified otherwise, formwork shall be Class F2. 3) Class F3 Finish: Permanently exposed, formed surfaces with high quality appearance. In addition to the requirements for Class F2 finish, formwork panels shall be arranged in a regular pattern with joints between panels vertical and horizontal. Panels that have been damaged or that have any holes (other than the tiebar holes in use) shall not be used. Internal ties shall be arranged in a regular pattern. Surfaces shall be rubbed with carborundum brick or other abrasive until uniform colour and texture are produced. Unformed finishes comprise: 1) Class U1 surface finish: This surface is required on those portions of the Works which are to receive concrete surfacing or which are to be covered by backfilling material, or as otherwise shown on the Drawings. On completion of placing and compacting the concrete the top surface shall be levelled and screeded off with a template to the required cross section and tamped with a tamping board to compact the surface thoroughly and to bring mortar to the surface, leaving a uniform surface to the profile shown on the Drawings. 2) Class U2 surface finish: Required on sidewalks; tops of wingwalls and retaining walls; exposed concrete shoulders and unsurfaced areas on bridge decks, and inverts of box culverts, or as otherwise shown on the Drawings. Page 32
The surface shall first be given a Class U1 surface finish and after the concrete has hardened sufficiently, it shall be wood-floated to a uniform surface free of trowel marks. For non-skid surfaces such as on sidewalks and bridge decks, the surface shall thereafter be given a broom finish. The corrugations produced shall be approximately 1 mm deep, be uniform in character and width and have a pattern perpendicular to the centre line of the pavement. 3) Class U3 surface finish: Required at bearing areas and tops of concrete railings, or as otherwise shown on the Drawings. The surface shall be given a Class U1 finish, and after the concrete has hardened sufficiently it shall be floated by means of a steel float under firm pressure to produce a dense uniform smooth surface to within the dimensional tolerances. Rubbing with carborundum stone after the concrete has hardened shall be allowed but under no circumstances will plastering be permitted. 427 Removal of Formwork
1) Formwork shall be removed without damage to the concrete, but not until the concrete has sufficient strength to support itself. Centres and props may be removed when the member has sufficient strength to carry itself and any loading with a reasonable factor of safety. External loading shall not be applied until the concrete has reached the 28-day Characteristic Strength. Formwork shall not be removed without prior approval. 2) The following is a guide to the minimum periods between placing and the removal of formwork:Vertical sides of beams, walls, columns - lift not exceeding 1.2m 12 hours - lift exceeding 1.2m 36 hours Soffits of main slabs and beams - props left under 5 days Beams and main slabs - removal of props
18 days
3) After removal, remedial work shall not be undertaken until the concrete has been inspected and approved. 428 Construction Joints
1) Concreting shall be carried out continuously up to construction joints, the position, arrangement and sequence of which shall be as approved by the Engineer, or as indicated on the Drawings. The Contractor is to allow for working beyond the ordinary working hours where necessary in order that each section of concrete may be completed without any lapse while the work is in hand. All construction joints are to be formed square to the work with keyways included. Page 33
2) Where vertical construction joints are required, the joint face of the first cast concrete shall be finished against a stopping-off board, or vertical end shutter, suitably notched to pass the reinforcement. When the concrete is hard and the shutter is removed, the whole joint surface shall be thoroughly roughened or scabbled with suitable tools so that no smooth skin of concrete is visible and that all aggregates and solid matrix around them is exposed; the aggregate shall not be damaged. 3) For horizontal or slightly inclined construction joints, the surfaces shall preferably be prepared when the concrete has set but not hardened by jetting with a fine spray of water and brushing with a stiff brush to remove the smooth skin and expose the aggregate without disturbing it. Where this treatment is impractical and work is resumed after the concrete surface has hardened, a similar procedure shall be adopted as on vertical joints. 4) If, in the opinion of the Engineer, any deleterious material has come into contact with the concrete of the construction joint or if the concrete is honeycombed or unsound for any reason, the concrete shall be cut back to such a depth as the Engineer shall order and the roughened surfaces shall be thoroughly cleaned by compressed air and water jets or other approved means. 5) Immediately before concreting is resumed, the roughened joint surface shall be thoroughly cleaned with compressed air and water jets and slightly wetted. The Contractor shall take precaution to avoid segregation of the concrete along the joint plane and to obtain thorough compaction. 429 Movement Joints
1) Movement joints shall include contraction joints, expansion joints, sliding joints and other special joints as may be detailed and shall be formed in the position and manner shown on the Contract Drawings. The concrete surfaces shall be plane and smooth and the Contractor shall ensure that there is no obstruction to free movement.
2) Where a movement joint includes a continuous waterbar, concrete shall be well worked around the embedded part of the waterbar and be free from honeycombing. Projecting portions of the waterbar shall be protected from damage during operations and, in the case of rubber and plastic, from light and heat. 3) Contraction joints shall be treated to prevent bond between joint surfaces by the application of two coats of an approved bond-breaking paint to the joint surface first constructed and allowing the paint to dry before placing new concrete against it. 4) Expansion joints shall be formed by a separating strip of preformed durable resilient joint filler which shall be continuous through the joint. No broken pieces of joint filler shall be used. Where dowel bars are to be incorporated in expansion joints, they shall be round mild steel bars conforming to the requirements of the steel reinforcement specification. The capped end of the dowel bar shall be sawn square
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and bar cropping will not be permitted. The capped section of the bar shall be painted with two coats of an approved bond-breaking paint. The cap shall be of such a diameter as to provide a sliding fit on the bar and shall be partially filled with approved compressible filler. 5) Joints shall be provided with waterbars, dowels, joint fillers, joint sealants, bondbreaking compounds and other jointing materials as specified or detailed on the Drawings. All such materials shall be as approved by the Engineer and their installation shall be strictly in accordance with the manufacturers instructions. If required by the Engineer, the Contractor shall demonstrate that the jointing materials can be applied satisfactorily. 6) Waterbars shall be manufactured of extruded PVC or nitrile rubber. They shall be of the types and general shapes specified on the Drawings. Waterbars shall be jointed by an approved jointing process. Waterbars shall comply with the requirements in the following table: WATERBAR CHARACTERISTICS AT 25C PROPERTY Density Hardness Softness Number Tensile Strength Elongation at Break Point Water absorption immersion) Web Thickness Centre Bulb Dimension (48 RUBBER - BS 903 1100 kg/m3 (+5%) 60 - 65 I.R.H.D. -> 20 N/mm2 > 450% hrs < 5% 10 mm 18 mm PVC - BS 2782 1300 kg/m3 (+5%) 70 - 75 I.H.R.D. 42 -52 > 15 N/mm2 > 285% < 0.7% 10 mm 18 mm
Rubber and PVC waterbars shall be suitable for storage, handling, installation and service within a range of 15C to 50C. Waterbars shall include means, such as eyelets or reinforced nailing flanges, to facilitate the accurate fixing within the structure.
430
Steel Reinforcement
1) Reinforcement for use in reinforced concrete shall comply where appropriate with IS432, IS 1786, IS 1566, IS 2062 2) High-yield deformed bars Fe415 shall be Type 2 complying with IS 1786 unless otherwise specified. Page 35
3) Reinforcement shall be cut, bent and fixed in accordance with IS 2502 4) The number, size, form and position of pieces of reinforcement shall be as shown on the Drawings. They shall be held in position in the formwork during the placing of concrete by use of distance pieces and spacer bars. 5) Links shall be taut so that bars are braced and the inside of their curved parts shall be in contact with the bars being connected. Tying wire shall be black annealed mild steel approximately 1.5mm diameter or similar approved twisted tight with pliers; the free ends shall be bent inwards. 6) Reinforcement shall be free from loose rust, oil, grease, salt and other deleterious matter. If necessary, reinforcement shall be cleaned by grit-blasting or wire brushing before use. Partially set concrete adhering to exposed bars during concreting operations shall be removed. 7) Reinforcement temporarily projecting from the concrete at joints shall not be bent out of position without approval, in which event the reinforcement shall be bent over a suitably sized former to prevent any damage or over stressing. 431 Storage of Reinforcement
1) Steel reinforcement shall be stored in an approved manner clear of the ground. 432 Cover to Reinforcement
1) The location of reinforcement and minimum dimensions of concrete cover shall be as shown on the Drawings. Where no such dimension is given, the minimum cover to links shall be 25mm and main bars 40mm. 2) Reinforcement shall be located within tolerances as specified herein. 3) When inspected in the forms, the cover to the reinforcement shall be the nominal cover within plus 10mm and minus 5mm tolerances. 4) Only approved spacers may be used in permanent works. Before spacers are approved for use in the works, their capacity to hold the reinforcement securely in position during concreting without detriment to concrete placement, compaction or durability shall be fully demonstrated. Concrete spacers shall be of similar concrete grade to the parent concrete and shall comply with the specified requirements for water absorption. 433 Curing and Protection
1) Concrete shall be wet cured continuously for a period of 7 days. Concrete shall be protected during the first stage of hardening from the harmful effects of sunshine, drying winds, cold, rain or running water. The Contractor shall pay particular attention to the need to protect concrete immediately after the finishing operation and prior to its final set. Protection of concrete, both horizontal and vertical surfaces,
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which has achieved its final set shall consist of the following: i) A layer of hessian, straw mats or similar absorbent material or a layer of sand shall be placed over the concrete and kept constantly moist by spraying with water, as necessary, for seven (7) days. ii) A layer of approved waterproof paper or plastic membrane shall be placed over the wet absorbent material to prevent evaporation and maintain in position for seven (7) days. 2) The use of saline water for curing purposes will not be permitted.
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PART 5: MASONRY AND STONEWORK

501 Stone
1) Stone for all purposes shall be the best of its kind, sound and durable, free from flaws and from soft, weathered or decomposed parts. The stone and the quarry from which it is obtained shall be subject to the approval of the Engineer. Samples shall be submitted by the Contractor of the stone he proposes to use in the Works and the Engineer's approval shall be obtained before such stone is used or any order is placed. The stone used shall be clean and must be washed if deemed necessary in the opinion of the Engineer. 2) Stones for face work shall be as far as possible quarry split and not bullnosed or hammer dressed. A moderate amount of dressing to trim off large projections will however be permitted. Exposed faces of stones for masonry shall be free from tool marks except such as are inherent in the nature of any dressing that may be specified. In masonry-lined waterways the roughness on the surface shall not project more than 30mm for stone less than 0.3 square metres face area and not more than 50mm for larger stones. 502 Masonry
1) Masonry shall be built to the lines and levels shown on the Drawings or required by the Engineer. Notwithstanding any local usage it shall be built in the manner specified below. 2) The stones shall be set in mortar with their natural bedding plane (if any) as near normal as possible to the face or normal to the line of thrust in the case of load bearing structures. Particular care must be given to obtaining a sound bond both longitudinally and transversely and there shall be at least one bonder, of length not less than two-thirds of the wall thickness, in each square metre of wall face. 3) Both faces of the wall shall be raised in lifts not exceeding 600mm high. The cavity between the faces shall be completely filled with mortar or concrete before proceeding with the next lift. 4) The mortar, unless otherwise specified, shall be Ordinary Portland Cement and sand mixed in the proportion of 1:4. Mortar shall completely fill all interstices between the stones. 5) The face joints in rubble masonry may vary in thickness from 10 mm to 20 mm. They shall be finished with mortar as a neat weathered joint while the work proceeds. 6) Before a general start on a structure of large dimensions is begun the Contractor will be required to build a small portion of the walling of required type for approval by the Engineer. After approval has been given, the remainder of the work will be required to conform to the samples.
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7) Building of masonry will not be allowed in heavy rain or at temperatures below 3oC without the written consent of the Engineer. 503 Random Rubble Masonry
1) Random rubble uncoursed masonry shall be built with stones of irregular shapes taken generally as they come from the quarry, preparation being limited to the removal of inconvenient corners and excrescences. They shall be selected as the work proceeds to give a uniformly random appearance and no attempt shall be made to form courses. All stones shall be carefully set with a bond stone provided at the rate of 1 to every sq.m. of exposed face. Bond stones shall measure not less than 150 mm by 150 mm on the exposed face, and not less than 450 mm in length or the full thickness of the wall if the latter is less than 450 mm. 2) Random rubble brought to courses shall be generally as the preceding type except that it shall be levelled up to courses between 300 and 400 mm in depth and coinciding with the quoin stones. Masonry Lining to Waterways
504
1) Masonry lining shall be built to the lines and levels shown on the Drawings or required by the Engineer. Notwithstanding any local usage it shall be built in the manner specified below. 2) The lining shall be formed as two layers infilled with mortar. The stones shall be set in mortar with a smooth face forming the surface of the waterway. Protrusions inside the line of the waterway shall be kept to a minimum and shall not exceed the dimensions specified in Clause 501 above. Particular care must be given to obtaining a sound bond both longitudinally and transversely, however, to avoid forming seepage paths, bonders (stones extending across the full thickness of the lining) shall not be used, 3) Both faces of the lining shall be raised in lifts not exceeding 600mm high. The cavity between the faces shall be completely filled with mortar or concrete before proceeding with the next lift. 4) The mortar, unless otherwise specified, shall be Ordinary Portland Cement and sand mixed in the proportion of 1:4. Mortar shall completely fill all interstices between the stones. 5) Before a general start on the lining is begun the Contractor will be required to build a small portion of the required type for approval by the Engineer. After approval has been given, the remainder of the work will be required to conform to the samples. 6) Building of masonry linings will not be allowed in heavy rain or at temperatures below 3oC without the written consent of the Engineer. 505 Stone Masonry Armouring to Weirs
1) Stone masonry armouring shall be provided where specified on the Drawings to give
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a hard wearing surface to weirs and other structures as shown on the Drawings. 2) The concrete surface on which the armouring is to be placed shall be clean and sound. The surface shall be mechanically roughened by scabbling or needle gun or manually with hammers to remove all laitence and produce a rough exposed aggregate finish. The surface shall then be thoroughly cleaned with air and/or water jets to ensure that it is free from dust, oil, grease or any other deleterious substance. The concrete surface shall be thoroughly dampened with water and any excess water removed before applying the bedding concrete. 3) The stone used for the stone armouring of weirs shall be extremely hard and durable, of the best of its kind and free from flaws, soft, weathered or decomposed parts. Samples of the stone proposed for use in the works shall be provided to the Engineer and written approval shall be obtained before such stone is used or any order placed. 4) The sizes and tolerances of the individual stones and face finishes are as given on the Drawings and as specified. The stones shall generally have an upper exposed face of 250mm x 250mm, but with an area not less than 0.05sq.m. The bottom face of the stone shall be parallel to the top in order to achieve a good bond with the bedding concrete. The bottom face shall generally be 200mm x 200mm; but with an area not less than 0.04sq.m. The overall depth of the stone shall be not less than 300mm and not greater than 450mm. the roughness on the exposed surface shall not project more than 25mm. 5) The stone armouring shall be laid, tamped and bedded in concrete to produce an exactly flat surface, level or sloping to the lines and levels shown on the Drawings. 6) The weir crest shall be exactly level as shown on the Drawings, with only variations due to the roughness of the stones. Along the crest line, no part of the stone surface shall be more than 5mm below or 30mm above the specified level. The tolerance on other faces of the weir, such as the upstream or downstream slopes and stilling basin, shall not exceed -20mm or +50mm for any point on the surface of the stone. 7) The individual stones shall be embedded in concrete Class M25/12. The Contractor shall carry out trials to determine the optimum mix and water/cement ratio which gives required characteristics for bedding and anchoring the masonry armouring with absolutely no voids between the stones. 8) The stone armouring shall be laid in an interlocking bond pattern as shown on the Drawings. Under no circumstances shall the joint between any stones in any two adjacent rows be aligned together in the direction of the water flow. 9) A priming layer comprising cement mixed with an approved Styrene Butadyne Resin (SBR) shall be used in accordance with the manufacturers application instructions. 10) The Class M25/12 concrete shall be applied in an even layer, of such depth and over such an area as will permit the masons to properly place and compact the stone into the wet concrete. The Contractor shall undertake such trials as are necessary in order to determine the optimum method of placing the stone in the wet concrete, the depth Page 40
of the concrete layer and the extent of the working area for the concrete and priming slurry in advance of the stone laying operation. The concrete and priming slurry shall be freshly laid and under no circumstances shall be reworked to increase workability. The stones shall be forced into the fresh concrete to the required level when the voids between the stone being laid and previous stones shall be completely filled with concrete and the concrete fines and grout is extruded through the joint between the stones at the top surface. On no account shall the joint between the stones be filled with concrete, mortar or grout from the top. Any final pointing or finishing of the joints between the stones shall only be carried out with the express written permission of the Engineer. 11) The Contractor shall obtain the written approval of the Engineer to the method of placing the stone following completion of the trials and prior to commencing the main works. Under no circumstances shall any deviation from the agreed placement method be considered without the written approval of the Engineer. 506 Dry Rubble Walling
1) Dry rubble masonry shall be constructed generally to the requirements for uncoursed random rubble masonry, as specified in Clause 503 but with the omission of mortar. All stones shall be carefully shaped to obtain as close a fit as possible at all beds and joints, any interstices between the stones being filled with selected stone chippings or spalls. The exposed tops or copings of dry rubble walls shall be formed as shown on the Drawings. 507 Hand-placed Rubble Filling
1) Hand-placed rubble filling shall consist of stones individually selected and placed by hand firmly in place in bearing contact with each other or with the sides of the space to be filled; the voids shall be carefully filled with small rock and spalls wedged together to form a compact mass. The sides of stones shall be roughly trimmed if necessary with a spalling hammer to obtain a reasonably close fit. On the exposed face the stones shall be placed with their flattened sides uppermost and in the place of the face. 508 Rubble Filling
1) Any filling for which "rubble filling" is specified shall be done with approved quarry run rock filling obtained from works excavations, from a borrow pit, or from any other source. The rock shall be dumped in such a manner that the filling will be adequately compacted. 509 Gabions
1) Gabions and mattresses shall be of the types and sizes shown on the Drawings or as specified by the Engineer. The cages shall be constructed from mild steel wire complying with Mild steel Wire for General Engineering Purposes (IS 280), galvanised in accordance with "Electro galvanised coatings on round steel wire" (IS 12753). The wire shall be 2.70mm diameter and formed into a fabric having a
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mesh of 80mm x 100mm for gabion baskets and 60mm x 80mm for mattresses. The fabric shall be of the "hexagonal double twist" type. 2) Stone filling for gabions shall consist of hard durable rock, and shall be free from weathered or decomposed parts. The minimum dimension of each stone shall not be less than half its maximum dimension. The stone shall be 200mm to 100mm size. The stone shall be obtained from a source approved by the Engineer. No stone shall be smaller than the size of the gabion mesh openings. In carrying out the filling, selected pieces of stone of elongated shape shall be placed with their flatter and elongated faces in contact with the mesh wherever possible. 3) The empty gabion baskets shall be placed to line and level as shown on the Drawings or as directed by the Engineer and then stretched so that the gabions retain their shape on being filled. Diaphragms shall be provided at not more than 1 metre intervals. The gabions shall be filled with approved stone by hand. No basket or mattress forming part of an intended continuous line of gabions shall be completely filled until an adjacent basket or mattress has been half filled, unless otherwise directed, in order not to cause displacements from bulging during filling. 4) For baskets at least two horizontal connecting wires shall be tied between front and back of the gabion in each 1 metre compartment, at a height of 330mm and 660mm from the bottom as the stone fill reaches these levels. Additional tie wires shall be provided if necessary and in no case shall the gabion basket bulge by more than 40mm. Where a continuous line of gabions is required, adjacent gabions shall be securely tied together at the top and bottom of the gabions with tying wire. 5) Particular care shall be taken to ensure tightness of mesh, well packed filling with minimum voids and secure lacing. 6) The gabions shall be filled to a level just sufficient to require the lid to be forced into place with a bar. The lid and all joints between basket and between diaphragms and basket shall each be tied down with a continuous running wire. 7) Where gabions are to be shaped, the shape shall be formed by folding the mesh internally and tying it with a continuous running wire. 8) All tying wire shall be 2.7 mm dia galvanized wire. 510 Rock Armouring and Rip-Rap
1) Rock armouring and rip-rap shall consist of selected rock or stone complying with Clause 501 of this Specification. 2) The maximum and minimum mass of individual rocks to be used in armour construction shall as stated on the Drawings. Where rock is detailed by size, the following grading shall apply:
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Nominal 1000mm Size (mm) %age passing 1500 100% 1000 50% 500 0%
Nominal 500mm Size (mm) %age passing 750 100% 500 50% 300 0%
3) Before placing armour, an area not exceeding 100 square metres, shall be clearly marked out upon the area to be protected. The Contractor shall place armour by means to be approved by the Engineer, on this area in such a thickness that the specified mass/m2 is achieved. In order that the requirements of the average mass specification above may be observed, all armour stone to be placed on the marked up area shall be weighed on a weigh bridge. 511 Filter Fabric / Geotextile
1) The filter fabric beneath gabions shall be of a non-woven melded fabric consisting of a mixture of polypropylene and polythene or other similar materials. The grade of the fabric shall weigh not less than 800gm/sq.m and have a minimum thickness of 6mm. Where overlapping of fabric is required, the overlap shall not be less than 500mm. 2) P80 as manufactured by Bidim will satisfy the above requirement. The Contractor may propose alternative suppliers for the Engineers approval. 512 Gravel Filter
1) A 150mm thick gravel layer shall be placed under riprap stone and gabion boxes and mattresses and over geotextile as shown on the drawings or as instructed by the Engineer. Gravel protection layer shall have the following characterisations: Gravel layer grading Particle diameter mm 5 20 50 513 Stone Pitching %age passing 0 50 100
1) Stone for pitching shall be obtained from an approved source and shall be hard, sound, durable, clean and generally follow the specification of stone for facing. The minimum dimension of any stone shall be at least equal to the specified thickness of the pitching. 2) After excavation and trimming, slopes to be pitched shall be spread with a 75 mm
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thick layer of crusher run rock or graded coarse aggregate ranging from 75 mm particle size of fines. The slope shall then be hand packed with hard broken rock to a total thickness of 150 mm, each stone being individually placed and rammed home, with smaller stones wedged into the cracks. 50 mm dia weep holes shall be provided at intervals not exceeding two metres in both directions.
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PART 6: ROADWORKS
601 Sub-grade Preparation 1) Before placing the gravel topping, the sub-grade shall be prepared to a depth of 200mm to remove debris and rock greater than 100mm before being mixed with water or left to dry to provide optimum water content within 3% of laboratory optimum. The surface shall then be graded to the correct profile and compacted with four passes of a vibratory steel drum roller with a static drum weight of at least 7 tonnes 602 Granular Sub Base (GSB) 1) The material used for Granular Sub Base shall be naturally occurring gravel or crushed rock complying with the following grading IS Sieve Size (mm) 75 20 2.36 (No 7) Percentage passing by Weight (Square Mesh) 100 40-60 0
2) Compaction shall be carried out by a minimum of three passes of a vibratory steel drum roller with a static drum weight of at least 7 tonnes and reach not less than 90% of the maximum dry density (laboratory Proctor compaction) at optimum water content as determined in accordance with IS 2720 (part 18). 603 Water Based Macadam (WBM) Road Surfacing 1) The material used for WBM top surface of roads, shall be naturally occurring gravel or crushed rock complying with the following grading, and capable of being compacted to achieve a well-knit dense layer. Natural Gravel Crushed Stone IS Sieve Size Percentage passing IS Sieve Size Percentage passing (mm) by Weight (mm) by Weight Square Mesh Square Mesh 37.5 20 10 5 2.36 (No 7) 0.6 (No 25) 100 80-100 55-80 40-60 30-50 15.30 50 37.5 20 10 5 2.36 (No 7) 0.6 (No 25) 0.075(No 200) 100 95-100 60-80 40-60 25-40 15-30 8-22 5-12
0.075 (No 200) 5-15
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2) Road surfacing material shall be spread evenly in layers and compacted thickness of each layer should not exceed twice the maximum size of stone. The layers shall be compacted to obtain a well-bound surface finish, any loose areas or segregated areas being made good by addition of fines or by removing and replacing with fresh material as directed by the Engineer. Fines should be less than 6.3mm maximum size, preferably well graded and must be non-plastic. 3) Compaction shall be carried out by a minimum of four passes of a vibratory steel drum roller with a static drum weight of at least 7 tonnes and reach not less than 95% of the maximum dry density (laboratory Proctor compaction) at optimum water content as determined in accordance with IS 2720 (part 18). 604 Road Maintenance
1) The Contractor shall maintain and repair the Access Roads until the Completion Date for the whole of the Works. 2) Maintenance and repair of the road shall include; but not be limited to; i) grading at regular intervals
ii) repairing of road surfaces iii) replacement of gravel topping iv) cleaning and repairing of ditches and culverts v) removal of debris including, rockfall, landslide, or stream deposits vi) dust control by application of water to the road surface. vii) filling and repair of Access Road washed away by floods or heavy rain
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PART 7: CULVERTS & DRAINAGE

701 Culvert Material
1) Unless otherwise shown on the drawings, culverts shall be NP4 pre-cast concrete pipe complying with (IS 458). All pipes shall have gasket type joints of spigot & socket, rebated or separate factory made collar form. 702 Unloading and Laying out Pipes
1) When delivered to Site, pipes shall be carefully unloaded without breakages. If the pipes have to be unloaded singly and by hand, skids and check ropes shall be used, and pipes shall not be dropped nor allowed to roll unchecked. Pipes shall be wedged together to prevent further movement. 703 Laying and Jointing Pipes
1) All pipe systems shall be laid to the lines and levels shown on the drawings. 2) Where ground water is encountered, it shall be kept below the sockets when jointing by means of pumping. 3) Each pipe shall be carefully lowered onto the prepared bed by means of the necessary slings and tackle. 4) No pipe or pipeline may be used for trench drainage purposes without the permission of the Engineer. 5) Unless otherwise approved by the Engineer, pipes shall be laid from the downstream end with the pipe sockets facing upstream. 704 Installation
1) At the downstream end erosion shall be prevented by masonry or stone pitching. 2) The excavation for the culverts shall be done to such a width that there is a free space of 500 mm between the pipes and the side of the excavation in order to allow for a careful packing of the backfill. 3) If the bottom of the excavation consists of rock or stones, a 200mm thick layer of well-compacted sand shall be placed at the bottom. 4) Filling around pipes shall be carried out concurrently on both sides in layers not exceeding 150 mm. Maximum size of stone close to the culvert shall be 40 mm. Packing shall be done so that no lifting or major deformation of the culvert takes place. Before any compaction of fill above the culvert takes place the fill thickness shall be at least 500 mm. 5) Backfill material shall not contain organic material and shall not contain more than 5% of material retained on a 19 mm sieve. The Contractor shall obtain the Engineer's approval of the backfilling material he proposes before any backfilling is carried out. Page 47
All equipment not required for compaction shall be kept a minimum distance of 3 metres from the sides of the culvert during backfilling. 705 Subsurface Drainage Slotted Plastic Pipework
1) Subsurface drainage shall comprise 200mm diameter slotted uPVC or Polyethylene slotted well casing with a minimum wall thickness of 8mm in accordance with IS12818. Slots shall be 1.0mm x 40mm length in accordance with the IS standard for well screen not exceeding 250m depth. 2) Joints may be threaded, solvent welded or O seal with factory formed threads or sockets respectively. All Tee pieces and bends shall be factory formed and jointed in accordance with the manufacturers recommendations in respect of general pipe jointing. 3) Plain pipe shall compatible with the slotted screen and of the same dimensions and wall thickness.
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PART 8: BUILDING FINISHING WORKS

801 General
1) This specification covers the requirements for building finishing works comprising brick and stone masonry, floorings, doors, windows, ventilators, wood/ aluminium work, water proofing, plastering, painting plumbing, sanitation, electrical fittings and such other related works forming a part of this job. The work under this specification shall consist of furnishing of all tools, plants, labour material and everything necessary for carrying out the work, 802 Applicable Codes and Specifications
1) The following specifications, standards and codes, including all official amendments/revisions and other specifications and codes referred to therein, should be considered a part of this specification. In all cases the latest issue/ edition/revision shall apply. In case of discrepancy between this specification and those referred to herein below or other specifications forming a part of this bid document, Engineers decision shall be required for interpretation. 2) Materials IS:280 IS:348 IS:412 IS:428 IS:702 IS:712 IS:777 IS:1038 IS:1077 IS:1081 IS:1124 IS:1477 IS:1542 IS:1597 IS:1661 IS:1834 IS:1838 Specification for mild steel wire for general engineering purposes. French polish Expanded metal steel sheets for general purposes Distemper, oil emulsion, colour as required Specification for industrial bitumen Specification for building limes Specification for glazed earthenware tiles Specification for steel doors, window and ventilators Specification for common burnt clay building bricks Code of practice for fixing and glazing of metal (steel and aluminium) doors, window and ventilators Method of test for determination of water absorption, apparent specific gravity and porosity of natural building stones. Code of practice for painting of ferrous metals in buildings (Part 1 and 2) Specification for sand for plaster. Code of practice for construction of stone masonry Code of practice for application of cement and cement-lime plaster finishes Specifications for hot applied sealing compound for joint in concrete. Specification for preformed fillers for expansion joint in concrete pavements and structures (non-extruding and resilient type): Part 1 Bitumen impregnated fiber. Ready mixed paint, air drying, red oxide-zinc chrome, and priming.
IS:2074
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IS:2114 IS:2116 IS:2185 IS:2202 IS:2212 IS:2250 IS:2338 IS:2395 IS:2402 IS:2572 IS:2645 IS:2690 IS:2691 IS:2721 IS:2750 IS:3067 IS:3068 IS:3384 IS:3536 IS:3696 IS:4021 IS:4351 IS:4948 IS:5318 IS:6248 IS:7452 IS:9862 IS:15489
Code of practice for laying in-situ terrazzo floor finish. Specification for sand for masonry mortars. Specification for concrete masonry units (Part 1, 2 and 3). Specification for wooden flush door shutters (Solid core type): (Part 1 and 2) Code of practice for brickwork. Code of practice for preparation and use of masonry mortars. Code of practice for finishing of wood and wood based materials (Part 1 and 2). Code of practice for painting Concrete, masonry and plaster surfaces (Part 1 and Part 2) Code of practice for external rendered finishers. Code of practice for construction of hollow concrete block masonry. Specification of integral cement waterproofing compounds. Specification for burnt clay flat terracing tiles: Part 1 Machine made. Specification for burnt clay facing bricks. Specification for galvanised steel chain link fence fabric Specification for steel scaffoldings Code of practice of general design details and preparatory work for damp proofing and waterproofing of buildings. Specification for broken brick (burnt clay) coarse aggregates for use in lime concrete. Specification for bitumen primer for use in waterproofing and damp proofing Specification for ready mixed paint, brushing, wood primer, pink. Safety code of scaffolds and ladders (Part 1 and 2) Specification for timber door, window and ventilator frames Specification for steel door frames Specification for welded steel wire fabric for general use Code of practice for laying of flexible PVC sheet and tile flooring Specification for metal rolling shutters and rolling grilles. Specification for hot rolled steel sections for doors, windows and ventilators Specification for ready mixed paint, brushing, bituminous, black, lead-free, acid, alkali, water and chlorine resisting Specification for plastic emulsion paint
803
Waterproofing Work
1) All surfaces to be waterproofed shall be dry, clean, smooth and free from dust and loose particles. Water proofing treatment shall be as per specifications of approved specialist waterproofing company and shall consist of brickbat coba covered with jointless waterproof plaster finished smooth with trowel in cement mortar with false marking of 30 mm squares.
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2) Waterproofing treatment shall be taken up the parapet walls to a height of about 300 mm in shape of round wattas or as directed by the Engineer. 3) Bitumen felt waterproofing - the layers of bitumen felt shall conform to IS:1322. The first layer of bitumen felt shall be bonded to the dry, clean and smooth concrete surface by bitumen bonding compound. Bitumen felt shall be Shalimar or similar approved, laid with 50 mm side laps and 75 mm end laps staggered. The felt shall be laid continuously over the surface of the roof and shall not be terminated at expansion joints. Hot bitumen shall be applied on clean, dry and dust free surface. Tarflet or similar approved equivalent shall be laid over it. Then stone grit-bitumen mix shall be spread and compacted to form a 25 mm thick layer. Where specified, precast concrete tiles/paving slabs on a mud bound sand mix base course shall be provided. 804 Damp Proof Course
1) Unless otherwise specified damp proof course shall be formed from bituminous felt conforming to IS:1322 with a minimum lap at joints of 150 mm. Material for damp proof course shall be subject to the Engineers approval. 805 Cement Plaster
1) Cement and Sand - Cement and sand shall conform to the Specification for Concrete Works. 2) Workmanship - All stone or brick masonry shall be thoroughly wetted and joints raked out to a depth of at least 20 mm and walls washed before any plastering is done. The surface shall then be rendered with a mortar of specified parts of cement and fine sand, to 20 mm thickness and specified roughness. The surface shall then be floated or set with a thin coat of 3 mm thick cement and polished well with a trowel or flat board. The cement mortar shall be used within 30 minutes after it leaves the mixing board or mill. Before any plasterwork is started patches of plaster 150 mm x 150 mm shall be put on at every 3 metres apart as gauges so as to ensure an even thickness throughout the work. Cement plaster shall be done in even squares or strips. Care shall be taken to keep the whole surface thoroughly wetted for at least a week. The finishing surface shall be as specified and directed. Neeru finish shall be applied to the prepared and partially set but somewhat plastic surface, with steel trowel to a thickness slightly exceeding 1.5 mm, (1/16) and rubbed down to 1.5 mm (1/16) thickness and polished to a perfectly smooth and even finish working from top to bottom 3) The junction between beams and brickwork shall be plastered after fixing the expanded metal wire mesh of 300 mm width. The wire mesh shall be of size 20 mm x 20 mm gauge thickness.
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806
Cement Pointing
1) General - Before pointing work is taken up, the old mortar in the masonry or pitching work shall be raked out of the joints at least to a depth of 20 mm. The dust shall be brushed out of the joints and the walls shall be well wetted with fresh water until the old mortar in the wall is set to the satisfaction of the Engineer. The pointing shall then be made with fine mortar, of cement and fine sand, in the proportions as specified. The joints shall be neatly defined by the joining, and the same shall be raised or sunk as directed. In no case shall false joints be allowed. The pointing shall be kept wet until the cementing material sets and becomes hard. The whole surface shall be left clean at the completion of the work. 807 Mosaic Flooring
1) Mosaic flooring shall comprise a mixture of white cement and coloured marble chips or similar approved coloured stone. Individual panels not exceeding 1m2 shall be separated by 4mm glass or plastic strips in a pattern approved by the Engineer. The whole of the area shall be wet ground and polished to give a dense even and polished surface. 808 Woodwork in Doors, Windows, Partition, Louvres, Railing etc
1) Wood used for all work shall be best of the respective class specified, and properly seasoned by at least 6 months air drying, suitable for joiners work, should be of natural growth, uniform in texture, straight grained, free from sapwood, dead knots, open shakes, boreholes, rot, decay and any all other defects and blemishes. 2) The thickness specified for joiners wrought timbers, are unless otherwise specified, prior to planning and 3 mm will be allowed from the thickness stated for each wrought faces. 3) All joining shall be wrought on all faces and finished off by hand with sand paper, with slightly rounded arises. 4) Door, windows and ventilator frames, transformers and mullions shall be rebated. The top framing member of doors and top and bottom framing of windows and ventilators shall project about 150 mm in brickwork. The vertical of door frames shall project about 50 mm below finished floor. Surface coming in contact with brickwork shall be painted with bitumen as directed by the Engineer. Each of the door and window frames shall be provided with 3 Nos. M.S. 225 x 25 x 6 mm flat spilt hold-fasts on each side. These hold fasts shall be embedded in masonry or concrete work. The work shall conform to IS:4021. 5) The doors shall be panelled or solid flush doors. Single Leaf Doors a. 3 Nos. heavy duty railway type butt hinges 150 mm long. b. Godrej 6 lever mortice lock with one oxidized brass 350 mm long 16 mm diameter aldrop and with handles on both sides 1 Nos. (chromium plated brass).
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c. d.
Tower bolt 300 mm long. Door stop 1 No.
Double Leaf Doors a. 6 Nos. heavy duty railway type butt hinges 150 mm long. b. Aldrop 1 No. c. Tower bolt 300 mm long, 2 Nos. d. Cast handles 4 Nos. e. Door stops 2 No. 6) Where the single leaf doors are 1200 mm wide the number of hinges used shall be four. Similarly, if the height of the door exceeds 2200 mm, the number of hinges shall be suitably increased. 7) Door closures shall be of heavy duty hydraulic type. 8) Panelled doors shall comprise of 250 mm wide bottom rail, 150 mm wide middle rail and all other rails middle, top and vertical 100 mm wide. All rails shall be 40 mm thick. Panels shall be 20 mm thick. 9) The type of window shall be as specified. All fixtures fixed to windows shall be oxidized brass fittings. Each shutter shall have one pair of hinges, two tower bolts (one 225 mm long and another 150 mm long), one handle and one hook with eye and pegstay. Ventilators shall have two mild steel holdfasts and hinges, one handle and one hook and eye at each and one small tower bolt in the centre. Where so directed by the Engineer, the doors and windows shall be provided with parliamentary type hinges at no extra cost. 10) The workmanship of all door and window shutters shall conform to the requirements of IS:1003 (Parts 1 and 2) and IS:2202 (Parts 1 and 2). If required, flush door panels shall be tested as per IS:4020 at no extra cost to the Engineer. 11) Cupboards, almirahs and shelves shall be provided as required by Engineer. The doors could be of either hinged type or sliding type as approved by Engineer. Fixtures and fittings shall be of standard make or as directed by Engineer. 12) Railings and architraves shall conform to the standard shape, or as approved, and fixed by means of screws (counter sunk or otherwise) or bolts. 13) The finish expected is of a very high order, complete in all respects and the work shall be free from blemish. 14) Iron bars or grills shall be provided in the windows or ventilators are of standard make or as directed by the Engineer. Glass louvered ventilators and windows where specified shall be provided. 15) Woodwork shall not be painted, oiled or otherwise treated before the Engineer has approved it.
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16) The whole of the woodwork shall first be treated with two coats of anti-termite wood preservative chemical of an approved make. All the wood shall thereafter be treated with primary coat of paint. The application of primer shall not be done within 24 hours of the application of the second coat of anti-termite treatment. 809 Glazing and Metal Doors and Windows
1) Glass Generally - Glass shall conform to the requirements of relevant IS codes and shall free from bubble, smoke wanes, air holes, scratches and other defects and shall be cut to fit the rebates with due allowance for expansion. 2) Sheet Glass - Sheet glass shall be flat, transparent and clear as judged by the unaided eye. It shall be free from cracks. Sheet glass shall be of B quality or ordinary quality and with appropriate thickness. Sheet glass used for glazing in building shall conform to IS:2825. Modulus of rupture of sheet glass shall be 380 kg/cm2. Density of sheet glass shall be 2500 kg/m3. Glazing - Putty for glazing to wood shall be prepared in accordance with IS: 1635. Glazing work in buildings shall conform to IS: 3548.
3)
4) Compound for glazing to metal is to be an approved special compound manufactured for the purpose. 5) Glass Blocks - Hollow glass blocks shall be Insulight as manufactured by Pilkingtons or similar approved. They shall be joined in cement mortar but the edge of the panel shall be set in non-setting mastic. 6) Where required, the blocks shall be set in a reticulated steel security frame. Steel frames for glass blocks shall have a thickness of 5 mm. There shall be no distortion in frames. The whole frame with the exception of lugs and external faces of channels shall be precoated with approved bitumen emulsion or galvanized after manufacture. 7) Fittings for Doors Two floor springs of suitable make such as Everite, Prabhat etc. or equivalent having double action spring, unless specified otherwise. Each door leaf shall be fitted with two Nos. of suitable size of aluminium anodized handles from extruded tube of 100 mm x 50 mm minimum. One leaf cut of two shall be fitted with tower bolt at top or bottom of 230 mm size of chromium plated brass. 6 lever brass lock concealed in section tube and open able from both sides with two keys. 8) Fitting for Windows One opener, one handle and 15 cm. long tower bolt of brass, chromium plated.
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9) Steel Window and Doors - Steel windows and doors, including folding doors shall be supplied complete with frames and fitted with door furniture. 10) Steel is used in fabrication of windows and door shall have a minimum thickness of 3 mm. 11) Steel frame for glass block windows shall have a thickness of 5 mm. There shall be no distortion in the frames. The whole frame with the exception of lugs and external faces of channels shall be precoated with approved bitumen emulsion or galvanised after manufacture. 12) Rolling Shutters - The rolling shutters shall conform to the size to fulfil functional requirements. The rolling slats shall be in one piece and be made of heavy gauge steel sheets minimum thickness 18 SWG. A cylindrical hood shall be provided on the top to enclose the shutter when it is open. The rolling shutters shall be provided with suitable locking arrangements and deep channel guides. For galvanised slats, deep channel guides shall preferably be in one piece. 810 Painting
1) Unless otherwise specified in the Drawings or Contract documents, painting shall generally be: Interior walls & ceilings Three coats water based plastic emulsion. Woodwork Pretreated as Clause 808, primed and finished with two coats synthetic enamel. Architectural steel work and exposed steel fittings In accordance with Clause 1012 2) The finished colour of all paint work is subject to the prior approval of the Engineer. If instructed by the Engineer, the Contractor shall prepare sample panels of at least 1 m2 at a location determined by the Engineer. 811 Water Supply and Sanitary Works
1) General - Plumbing shall be carried out by a specialist Sub-Contractor approved Engineer and all works shall conform to the requirements of Engineer and the relevant Indian Standards. Building drainage shall conform to IS:1742. Water supply to buildings shall comply with IS:2065. 2) Applicable Codes - The following Indian Standard Codes, unless otherwise specified herein, shall be applicable. In all cases, the latest revision of the codes shall be referred to. IS:1172 IS:1239 Code of basic requirements for water supply, drainage and sanitation Specification for mild steel tubes and wrought steel fittings (Part 1 MS pipes), to be read in conjunction with IS 4736 (Hot dipped zinc coatings to MS tube) Code of practice for building drainage Page 55
IS:1742
IS:4111 IS:3114 IS:783 IS:4127 IS:5329 IS:2065
Code of practice for ancillary structures in sewerage system (Parts 1 and 2) Code of practice for laying of cast iron pipes Code of practice for laying of concrete pipes Code of practice for laying of glazed stoneware pipes Code of practice for sanitary pipe work above ground for buildings Code of practice for water supply in buildings
3) PVC Pipes - The Contractor shall install PVC pipes in the location and to the lines grades and dimensions according to detailed design drawings. Plastic pipes for subsurface drainage shall be in accordance with Sub-clause 705 of this Specification. 4) Galvanised Steel Tubing - Galvanised mild steel tubing and fittings shall be steel tube for water supply to IS:1239 Class M galvanised in accordance with IS:4736. All pipes shall be supplied by an approved manufacturer with screw and socket joints, tested hydraulically to a pressure of 48 bars. Pipes shall be secured to structures at not more than 1.5 centres, with galvanized malleable cast iron brackets of an approved pattern. 5) Cocks and Valves - All cocks and valves shall be of types approved by the Engineer and in accordance with IS:6157. Stop valves, which are generally concealed, shall be made of brass or gunmetal. Stop cocks, which are exposed and bib and pillar cocks attached to sanitary fittings shall be brass or gunmetal bodies chromium plated and marked hot or cold as required. 6) Ball valves shall be brass in accordance with IS:1703. 7) Water Pipes and Fittings - All plumbing works shall be carried out through a Licensed Plumber and the pipes and fittings shall be as per the requirements of the water byelaws. The Contractor shall submit the name of the Licensed Plumber to whom the work is to be entrusted for approval of the Engineer. On completion of the work the Licensed Plumber shall submit a Drainage Completion Certification, certifying that the works carried out by him have been done in accordance with specifications and provisions of and the relevant byelaws. 8) Glazed Stone Work - The pipes used in the works shall be of the best approved quality. All pipes shall be perfectly straight and truly cylindrical, glazed inside and outside, free from cracks and flaws, and perfectly burnt. Those not perfectly straight and truly cylindrical, well and uniformly glazed, free from cracks and flaws etc. shall be rejected. 812 Electrical Works
1) The general layout of electrical works shall be submitted by Contractor to the Engineer for approval. The Contractor shall then submit a detailed layout of each building to the Engineer for approval before commencing the works. 2) Samples of all important material including PVC conduits, wire, ordinary wires, for
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power points, switches, holders, tubelight fittings, cutouts & boards shall be submitted to the Engineer for his approval. 3) In general surface mounted GI conduit shall be used. Where specified, 25 mm dia PVC pipes shall be used for concealed wiring. 813 Roof sheets and vertical cladding
1) Unless otherwise specified on the drawings or specified elsewhere, roof sheets and vertical cladding shall be factory colour-coated steel profile sheet with a minimum steel thickness before coating of 1.0mm (20 gauge sheet). 2) The spacing of purlins and supports shall be in accordance with sheet sizes and laps recommended by the manufacturer but, in general, the maximum spacing of supports shall be 1.8m. 3) Fixings and laps shall be in accordance with the manufacturers recommendation but, in general, laps shall be 150mm for sheet ends and one full profile section for edges. Factory made edges for corners and ridge pieces shall be used. 4) Where shown on the drawings or specified elsewhere, translucent panels and/or louvre ventilators from the same manufacturer/cladding system shall be used. All ventilators shall be provided with heavy duty compatible metal wire insect and bird proof mesh. 5) Prior to ordering, the Contractor shall supply samples of the proposed sheets, translucent panels, ventilators and colour samples for the Engineers approval. 814 Fencing
1) Unless otherwise specified on the drawings or specified elsewhere, fencing shall be galvanised steel chain link fence fabric to IS: 2721 with a minimum steel wire thickness before coating of 4.0mm (8 gauge). The fabric shall be formed from continuous, single-interlocked, wires across the width of the fabric to form a diamond mesh of 50mm x 50mm. 2) All straining and edge wires shall be similarly galvanised steel wires 4.0mm diameter. 3) Unless otherwise specified, the wire shall be left as factory finished galvanised coating without plastic coating or paint treatment.
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PART 9: EARTH MAT

901 General Description
1) The earth mat shall comprise steel strips 75mm x 8mm laid in a grid pattern beneath the foundations of Power House, Tail Race and Switchyard. The Engineer will carry out measurements of ground conductivity, following which he shall instruct the spacing of earth strips and the area of the mat. 2) Steel strips shall be welded at every intersection to form a continuous mat. 3) Earth straps of 50mm x 6mm steel strips shall be connected to the earth mat at locations to be directed by the Engineer and brought to the surface at the locations of plant foundations. 4) The earth mat and earth straps shall be protected against damage from subsequent construction operations. 902 Earth Rods
1) Earth rods shall be installed below the earth mat at locations to be directed by the Engineer. The number of rods shall be instructed following the ground conductivity measurements. 2) The mild steel earth rods shall be 32mm diameter solid steel 3m in length. The top of each rod shall be connected with 75mm x 6mm steel flats to the earth mat through welded joints.
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PART 10: STEELWORK

1001 Hot Rolled Steel 1) Hot rolled steel in hot rolled sections, structural hollow sections, plates and bars shall comply as a minimum with the basic specification of IS 1732. All steel shall have been tested in accordance with IS 1732 and the Contractor shall obtain the relevant manufacturers test certificates. 2) Except where otherwise specified, structural steel, connections and fittings shall be grade 250. 3) All steel materials shall comply in dimension, weight and tolerance with those shown on the drawings and with the following standards: (i) (ii) (iii) (iv) 1002 Surface Condition 1) Steel surfaces when used shall not be more heavily pitted or rusted than Grade C of the Swedish Standard SIS 05 59 00. 2) Surface defects in hot rolled sections, hollow sections, flats, rounds and square bars revealed during surface preparation which are not in accordance with the requirements of IS 1732, for quality of finished steel, shall be rectified in accordance with clause 9 of IS 1732. 1003 Structural Fasteners 1) Bolts, nuts and washers etc, shall be of mild steel unless otherwise specified. The heads of the bolts shall be forged out of the solid bar and the ends shall be cleanly cut with standard threads and the nuts must fit the bolts accurately and tightly. Shop, site bolts, nuts and washers shall conform to following relevant standards: IS 3757 High Strength Friction grip bolts IS 6623 High Tensile Friction grip Nuts IS 6639 Hexagon Bolts for Steel Structures IS 6649 High Tensile Friction Grip Washers IS 7215 Tolerance for fabrication of steel structures Any bolt assemblies which seize when being tightened shall be replaced. 2) Plain metal washers shall be made in accordance with IS 6610- 1972. Black metal washers to Form E shall be used unless otherwise specified. Plates and bars IS 1732 Universal beams, columns, rolled joists, channels And tees IS 808 & IS 1170 Angles IS 808 & IS 1170 Structural hollow sections IS:1161 and IS 806
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1004 Welding Consumables 1) Consumables for use in metal arc welding shall comply with the requirements of IS 814 Part 1 and Part 2 & IS 1149 as appropriate. 2) Consumables shall be stored in the Contractors works and on site in a controlled atmosphere, in accordance with relevant Indian Standard. Any drying and baking of consumables before issue shall be carried out in accordance with the manufacturers recommendations and the authority of the Engineer. 1005 Corrosion Protection System 1) Material for blast cleaning shall be chilled iron shot in accordance with relevant Indian Standard. 2) Surface coatings shall be in accordance with the guidance given in IS 1477 and IS 2544 1006 General Workmanship 1) All steel shall be covered by a test certificate. The material grades of all steel shall be identifiable. 2) Individual pieces of steelwork shall be capable of positive identification at all stages of fabrication. Completed components shall be marked with a durable and distinguishing erection mark in such a way as not to damage the material. 3) Steelwork shall be bundled, packed, handled and transported in a safe manner so that permanent distortion does not occur and surface damage is minimised. 4) Cutting and shaping of steel may be carried out by shearing, cropping, sawing, nibbling, laser cutting or machine flame cutting, except where machine flame cutting is impractical, hand flame cutting may be used. Flame cut edges which are free from significant irregularities shall be accepted without further treatment except for the removal of dross, otherwise cut edges shall be dressed to remove irregularities. 5) The thickness of elements shown on the drawings as requiring machining shall mean the minimum thickness after the machining operations. 6) Cut edges shall be dressed to remove dross, burrs and irregularities. Holes shall be dressed as required to remove burrs and protruding edges. Sharp edges shall be dressed, but a 90 rolled, cut or sheared edge is acceptable without further treatment. 7) All matching holes for fasteners or pins shall register with each other so that fasteners can be inserted without undue force through the assembled members in a direction at right angles to the faces in contact. Drifts may be used but holes shall not be distorted. 8) Drilling shall be permitted through more than one thickness where the separate parts are tightly clamped together before drilling. The parts shall be separated after
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drilling and any burrs removed. 9) All components shall be assembled within tolerances specified and in a manner such that they are not bent, twisted or otherwise damaged. Drifting of holes to align the components shall be permitted, but must not cause damage or distortion to the final assembly. 10) When it is necessary to introduce or correct camber, or to straighten components, one of the following methods may be used: i) mechanical means, taking care to minimise indentations, or change of cross section.
ii) the local application of heat, ensuring that the temperature is carefully controlled, and does not exceed 600C. 11) Sufficient components shall be checked for dimensional accuracy and conformity to drawing to prove that the manufacturing process is working satisfactorily. 12) Fabricated components which are stored prior to being transported or erected shall be stacked clear of the ground and arranged so that water cannot accumulate. They shall be kept clean and supported in such a manner as to avoid permanent distortion. 1007 Welding Workmanship 1) Welding shall be a metal arc process in accordance with IS 816 and IS 9595, as appropriate, unless otherwise specifically permitted by the Engineer. 2) The Contractors proposed welding procedures shall be submitted in writing to the Engineer for his approval before any work is undertaken. The procedure shall identify material, weld geometry, tolerances, welding process, pre-heat temperature and welding position to be used. In the case of site welds, the welding procedure for making each type of joint shall be approved by the Engineer before the work is commenced. 3) All welding shall be carried out by qualified welders who shall be under competent supervision. The Engineer may call for a test of a welders capabilities in accordance IS 817 and IS 7310, as deemed appropriate. In the case of site welds the Contractor shall make such trial welds as the Engineer may require to demonstrate the soundness of the proposed method and the competence of his workmen. 4) The results of non-destructive testing of welds shall be recorded and be available for inspection by the Engineer. Visual inspection shall be made in accordance with guidance given in IS 7318 after completion of all welding over the full length of the weld. Any welds which will be rendered inaccessible by subsequent work shall be examined prior to the loss of access. Where a closer examination of a weld surface is required dye penetrant inspection may be used in accordance with the recommendations given in IS 7215. Any welds that are in the opinion of the Engineer defective, shall be cut out and the welds remade to the satisfaction of the
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Engineer. The cost of such corrective measures including any resultant delays, shall be borne by the Contractor. 1008 Bolting Workmanship 1) Washers shall be placed under the nut or bolt head being rotated when the members are being connected. 2) Connected parts shall be firmly drawn together. If there is a remaining gap which may affect the integrity of the joint, it shall be taken apart and a pack inserted. 1009 Erection of Steelwork 1) A method statement, giving details of the erection scheme and programme, shall be submitted to the Engineer for his approval, before erection commences. 2) Components shall be handled and stored in such a manner as to minimise the risk of surface abrasion and damage. Fasteners and small fittings shall be stored under cover in dry conditions. Any steelwork damaged during transportation, off-loading, storage or erection shall be restored to conform to the standards of manufacture as specified. 3) The Contractor shall ensure that all supports upon which the steel gates are to be erected are in the correct position and that the steelwork fits correctly in required positions without forcing or straining in any way. Any check by the Engineer of the Contractor's measurements shall not relieve him of his responsibility for obtaining this fit unless any errors in position are clearly not attributable to him. 4) No permanent bolting or site welding shall be done until proper alignment has been obtained. The Contractor may use temporary jigs, anchors or supports during erection, but must allow for thermal movement to take place freely at all times. 1010 Protective Treatment - General
1) The Contractor shall submit to the Engineer for his approval details of the types and manufacturers of paints he is proposing to use, together with the manufacturer's recommendations concerning preparation of surfaces, primers and undercoats, application methods, safety precautions and drying times for each type of paint. All paints used in the Works must be supplied ready-mixed in unbroken, sealed containers, which clearly show the type, colour and manufacturer of the paint and carry detailed "instructions for use". 2) All metal surfaces on which paint is to be applied shall be blast cleaned to grade SA 2 , or other approved mechanical means and fully prepared in accordance with the manufacturer's recommendations. Applications of paint coatings on external work shall not be carried out or continued in mist, rain or excessively damp conditions. The Contractor shall take all necessary precautions to prevent dust and dirt coming into contact with freshly applied paint before it has dried. 3) Paints shall be applied either by brushing or spraying in accordance with the
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manufacturer's instructions. The thinning of paints shall not be permitted without the approval of the Engineer. Unless otherwise recommended by the manufacturer, the minimum interval between the application of a first coat of paint and the second shall be twenty four hours (24hrs). Special care shall be taken to ensure complete coverage of all corners, arises and openings without causing an excessive build-up of paint and avoiding runs. 4) Steelwork to be painted shall be clean and free from all rust, grease, oil and mill scale. 5) The Contractor shall provide a magnetic paint thickness gauge or other suitable instrument for measuring paint thickness. 1011 Protective Treatment - Particular
1) Steelwork shall be immediately coated before leaving the factory with zinc phosphate or similar compatible metallic inhibitive primer with a minimum dry film thickness of 0.05mm. Following drying of the primer, the steelwork shall be coated with one coat of non-toxic, non-tainting, high build bituminous paint to IS 1477 part 1 & 2, having a minimum dry film thickness of 0.125mm. 2) After erection, damaged areas of steelwork shall be mechanically cleaned and touched up with primer and bituminous paint to fully restore the factory applied coating system and thickness. 3) Finally, two overall finish coats of bituminous paint with a minimum dry film thickness per coat of 0.10mm giving an overall minimum dry film thickness of the complete coating system of 0.375mm. 1012 Painting Handrails 1) Handrails shall be thoroughly cleaned and painted prior to leaving the factory with: i) one coat of zinc phosphate or similar compatible metallic inhibitive primer with a minimum dry film thickness of 0.05mm.
ii) one coat of red lead primer with a minimum dry film thickness of 0.05mm. iii) two coats of micaceous iron oxide undercoat paint with a minimum dry film thickness per coat of 0.05mm. 2) After erection, damaged areas of steelwork shall be mechanically cleaned and touched up with primer and under coat to fully restore the factory applied coating system and thickness. 3) Finally, one overall finish coat of enamel gloss micaceous iron oxide paint with a minimum dry film thickness of 0.05mm giving an overall minimum dry film thickness for the complete coating system of 0.25mm.
Page 63
Appendix A: Primary Survey Stations

DETAILS TO BE ADVISED PRIOR TO START DATE
Page 64
Appendix B: Table of Tolerances

The following are the tolerances within which the works are to be executed or as directed by the Engineer: EARTHWORKS Top level of Embankments after compaction Sides of Embankments over a 10m length Channel (or Excavation cutting) over a 10m length Channel Water Way Area Horizontal Alignment of Channels Maximum Over 20m length Maximum Over 20m length +100/-0 mm +100/ -0 mm +100/ -0 mm -0 300 mm 75 mm +100/-100 mm 50 mm +0/-ve (filled with concrete refer specification) +0/ -100 mm
Vertical Alignment of Channels
Formation Level for Structures
Formation Level for Gabions CONCRETE STRUCTURES
The following tolerances shall apply to all wrought formed and fair or fine unformed finishes. Tolerance from Specified Position Maximum departure of plan position of structure Tolerance from Specified Dimension Maximum departure in thickness, cross-sectional dimension or position of columns, beams, walls, footings and the like 300 mm
+15/ -5 mm
Page 65
Surface Tolerance on Straightness or Departure from Specified Curve General Surfaces Maximum deviation in horizontal or vertical direction gradual over a 10 metre length abrupt Surfaces in Contact with Flowing Water Maximum deviation in direction of flow or normal to flow gradual over a 10 metre length abrupt Reinforcement Maximum departure in required spacing Stonework Masonry on weir crest over a 2 metre length Masonry on other weir faces over a 2 metre length mm Ashlar masonry over a 2 metre length Masonry in hydraulic structures over a 2 metre length Masonry walls over a 2 metre length Face of gabion basket Thickness of gravel layer Thickness of tipped rock Steelwork Fabricated steelwork Machined steelwork +1/ -1 mm +0.1/ -0.1 mm +5/ -5 mm +10/ -10 mm +75/ -25 mm +50/ -25 mm +50/ -10 mm +100/ -0 mm +5/ -5 mm +10/ -10 +10/ -5 mm 10 mm 2 mm 25 mm 5 mm
Page 66
Tender Documents Specification: Volume II B Hydro Mechanical
KHIRAOGANGA HYDRO ELECTRIC PROJECT
VOLUME II-B
DESIGN MEMORANDUM AND TECHNICAL SPECIFICATION FOR HYDRO MECHANICAL WORKS
Tender Documents Specification: Volume II B Hydro Mechanical
INDEX
PART A - GATES, STOPLOGS, TRASHRACKS AND HOISTS
SECTION 1 - GENERAL DESCRIPTION OF EQUIPMENT 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 GENERAL DIVERSION WIER UNDERSLUICE GATES DIVERSION WEIR UNDERSLUICE STOPLOGS INTAKE GATE INTAKE STOPLOG INTAKE TRASHRACKS DESILTING GATE OF DESANDER HRT INTAKE TRASHRACKS DRAFT-TUBE GATE ROPE-DRUM HOISTS MONO-RAILHOIST TECHNICAL SPECIFICATIONS AND REQUIREMENT 17 17 19 20 20 22 23 24 27 29 32 34 37 38 1 1 3 5 7 8 9 11 12 14 16
SECTION 2 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 GENERAL
DESIGN AND STRESS LEVEL PERMISSIBLE STRESSES DESIGN CODES MATERIALS EMBEDDED FRAMES FOR GUIDES AND WHEEL PATHS ELECTRICAL EQUIPMENT SHOP ASSEMBLY AND TESTING SITE TESTING AND COMMISSIONING WELDING PROCEDURE NON-DESTRUCTIVE TESTS/INSPECTION SURFACE PREPARATION AND PAINTING INSTALLATION, OPERATION AND MAINTENANCE MANUALS ERECTION TOLERANCES
Tender Documents Specification: Volume II B Hydro Mechanical Part A
PART A - GATES, STOPLOGS, TRASHRACKS AND HOISTS SECTION 1 1.0 GENERAL The equipment included in the scope of work shall be as per general description given here under and as shown in the appended drawings, suitable for operating functions as defined. It shall be simple in design and give long trouble free service with minimum maintenance. Any item which is essential for the efficient performance of the equipment but not specifically mentioned in these specifications shall be considered included in the Scope of supply of the contractor. 1.1 DIVERSION WEIR UNDERSLUICE GATES The gates are vertical lift, fixed wheel type and having skin plate & seals on the upstream side designed to withstand full static head corresponding to Reservoir Level as indicated in the data given hereafter. The lowering/raising of gates shall be under unbalanced head conditions and therefore these shall be capable of gravity closing (i.e. due to weight of gate) under these conditions. The gates shall normally remain closed. When the water level in the reservoir starts exceeding the reservoir level EL 2454.62 m, the raising of the gates shall start. For operation of gates, rope drum hoists shall be provided. The gates shall be operated from the Local Control panel located on the top of piers near the gates. The gates shall be of fabricated steel construction consisting of upstream skin plate, horizontal girders and vertical stiffeners spaced according to design loads, end vertical girders and wheel assemblies mounted in between end vertical girders. Each gate shall have two lifting points and shall be provided with seals on upstream sides. Side & top seals shall be of rubber / Teflon cladded rubber music note type and bottom seal shall be of rubber wedge type. The seals shall be fastened to gate using stainless steel bolts/counter sunk screws and nuts. To limit the sway of the gate during operation, two guide shoes shall be provided on each side of the gate, which will remain engaged with embedded guides. The gates operate within fabricated steel gate frames embedded in concrete. The gate frame consists of wheel tracks (base of structural steel and track of corrosion resisting steel); side and bottom seal seats (Base of structural steel and faces of corrosion resisting steel) and structural steel guides. Each gate is operated by independent electrically operated rope drum hoist consisting of central drive unit (electric motor), reduction unit, shaft, rope drums, etc. Provision in the hoist mechanism shall also be made to operate it manually in the event of power failure. The hoists shall be installed on hoist bridge supported above top of piers. Access ladders shall be provided on each side of hoist bridge. Local
Part A 1
GENERAL DESCRIPTION OF EQUIPMENT
Tender Documents Specification: Volume II B Hydro Mechanical- Part A
controls for all the hoists shall be housed in a Control Panel located on top of piers / abutments. Data i) Type of Gate : Fixed wheel with upstream skin plate and upstream seals, regulating type i.e. may be kept at partial opening. :2 :2 : 2500 mm : 3000 mm : 2650 mm : 3000 mm : 3100 mm : 2448.00 M : 2454.62 M : 2456.50 M : 2451.00 M : 7.00 M (Including 0.32 free board) Wheel mounted on corrosion resisting steel axle with roller bearings and having line contact with track. Music note (hollow) rubber cladded / rubber. Rubber, wedge
ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) xiii)
No. of Bay No. of gates Clear width of opening Clear height of opening c/c of side seal seats c/c of track plates
C.L. of top seal seat ( from sill) Sill level Reservoir Level Level of Top of Structure Level of bottom of breast wall Design head
xiv)
Type of Wheel Assembly :
xv)
Type of side & top seals
xvi)
Part A
Type of bottom seal

2
xvii)
Position of skin plate & side seal : :
Up Stream 50 cm/min
(xviii) Lowering/raising speed of hoist xix) Operation :
Lowering / raising under un-balanced head conditions by Rope Drum Hoist.. Wet & Accessible, IS: 4622 : M-30 Min.
xx)
Permissible Stresses
(xxi) Second stage concrete in block-outs 1.2 DIVERSION WEIR UNDERSLUICE STOPLOGS
Provision to close the bays of the Weir by stoplogs has been made to facilitate repair and maintenance of one Weir Gate at a time. For this purpose stoplog grooves have been provided on upstream of Weir Gates. The stoplogs shall be lowered/raised under balanced head conditions i.e. under no flow conditions. A set of stoplog gate shall consist of not more than two units of almost equal height. Each stoplog unit shall be capable of self closing i.e. by gravity under its own weight. Embedded metals for stoplog gates shall be provided in all the weir bays. Stoplog units when not in use shall be supported on dogging latches provided near the top of the structure. The stoplog is vertical lift, slide type of fabricated steel construction and shall be formed by two vertical end girders between which horizontal girders are spaced according to design loads and the downstream face is covered with a skin plate. The stoplog in two Non Interchangeable of equal size units is provided with two lifting lugs. Stoplog units shall be provided seals on downstream side. Side seals shall be of rubber music note type and bottom seal of rubber wedge type. The seals shall be fastened to the stoplog unit using stainless steel bolts and nuts. Stoplog unit shall be provided with two guide shoes on each side. The stoplog units shall be handled by a monorail hoist using a lifting beam capable of grappling and ungrappling of stoplog unit under water. The lifting beam shall be attached to the hoist at two points. Two filling valves of 150 mm dia. shall be provided in the top unit of stoplog for creating balanced head conditions. Fabricated steel frames shall be provided in the weir bays to receive the stoplog. The frames shall consist of side and bottom seal seats, tracks i.e. load carrying faces to bear the thrust pads fixed on the stoplog units and guides on both ides. Faces of seal seats and tracks shall be of corrosion resisting steel. The Mono-rail Hoist shall be installed on steel structure above stoplog grooves. Electric power will be provided through a trailing cable and reeling drum
Part A 3
arrangement. Necessary brakes, overload protection, interlocks etc. shall be provided. All drive and hoist gears will be fully enclosed. Data i) Type of Stoplog gate: Vertical lift, slide with down stream skin plate and downstream seals, non-regulating type i.e. not to be kept at partial opening. ii) No. of Bays : 2
iii) No. of stoplog gate sets required: One iv) Clear width of opening v) Clear Height of stoplog vi) C/C of side seal seats vii) C/C of Track Plates : : : : 2500 mm 3000 mm 2650 mm 3000 mm 3100 mm 2448.00 m 2454.62 m 2456.50 m 2451.00 m 7.00 (Including 0.32 m free board) Rubber, music note (hollow). Rubber, wedge Down Stream Dry & Accessible, IS:5620
viii) C.L. of top seal seat (from sill) vi) Sill level vii) Reservoir Level : :
viii) Top of civil structure level : ix) Breast Wall bottom level x) Design head xi) Type of side seals xii) Type of bottom seal : : : :
xiii) Position of skin plate & seals xiv) Permissible Stresses xv) :
Lowering / raising speed of hoist : 0.75 m/min to 1.5 m/min : 4.0 m / min. to 8.0 m / min.
xvi) Traveling speed of hoist
Part A
xvii) Operation : Lowering / raising under balanced had conditions by Mon-rail Hoist. & Lifting Beam of adequate capacity xviii) Second stage concrete in block-outs 1.3 INTAKE GATE The gate is vertical lift, fixed wheel type and having skin plate & seals on the upstream side designed to withstand full static head corresponding to Reservoir Level as indicated in the data given hereafter. The lowering/raising of gate shall be under unbalanced head conditions and therefore this shall be capable of gravity closing (i.e. due to weight of gate) under these conditions. For operation of gate, rope drum hoist shall be provided. The gate shall be operated from the Local Control panel located on the top of abutments near the gate as well from the Control panel located in the Power House Control Room. The gate shall normally remain open and shall be closed in emergency from remote control panel installed power house or it shall be for planned repairs / maintenance of penstock etc. from the local control panel. The gate shall be of fabricated steel construction consisting of upstream skin plate, horizontal girders and vertical stiffeners spaced according to design loads, end vertical girders and wheel assemblies mounted in between end vertical girders. The gate shall have two lifting points and shall be provided with seals on upstream sides. Side seals shall be of cladded rubber music note type and bottom seal shall be of rubber wedge type. The seals shall be fastened to gate using stainless steel bolts/counter sunk screws and nuts. To limit the sway of the gate during operation two guide shoes shall be provided on each side of the gate, which will remain engaged with embedded guides. The gate operates within fabricated steel gate frames embedded in concrete. The gate frame consists of wheel tracks (base of structural steel and track of corrosion resisting steel); side and bottom seal seats (Base of structural steel and faces of corrosion resisting steel) and structural steel guides. The gate is operated by an electrically operated rope drum hoist consisting of central drive unit (electric motor), reduction unit, shaft, rope drums, etc. Provision in the hoist mechanism shall also be made to operate it manually in the event of power failure. The hoist shall be installed on hoist bridge supported above top of abutments. Local Controls for the hoist shall be housed in a Control Panel located on deck top of the abutments near the gate. The remote control panel shall be installed in the control room of power house. Data
Part A 5
: M-35 Min.
i) Type of Gate
ii) No. of Bays iii) No. of gates iv) Clear width of opening v) Clear Height of gate vi) C/C of side seal seats vii) C/C of Track Plates
: Fixed wheel with upstream skin plate and upstream seals, regulating type i.e. may be kept at partial opening. : One : : : : : One 3000 mm 1400 mm 3150 mm 3500 mm 1500 mm 2449.50 m 2454.62 m 2456.50 m 2450.90 m 5.5m (Including 0.38 free board) Wheel mounted on corrosion resisting steel axle with spherical roller bearings and having line contact with track. Rubber, music note cladded : Rubber, wedge : 50 cm/min
viii) C.L. of top seal seat (from sill): ix) Sill level x) Reservoir level : :
xi) Top level of civil structure : xii) Breast wall bottom level xiii) Design head : :
xiv) Type of Wheel Assembly:
xv) Type of side seals : xii) Type of bottom seal
xiii) Lowering/raising speed of hoist xiv) Operation :
Lowering / raising under un-balanced head conditions by Rope Drum Hoist. : M-30 Min. Wet & Accessible, IS: 4622
xv) Second stage concrete in block-outs xvi) Permissible Stresses

Part A 6
1.4
INTAKE STOPLOG
Provision to close the bay of the Intake by stoplog has been made to facilitate repair and maintenance of one Intake Gate whenever required. For this purpose stoplog grooves have been provided on upstream of Intake Gate. The stoplog shall be lowered/raised under balanced head conditions i.e. under no flow conditions. The stoplog shall be capable of self closing i.e. by gravity under its own weight. Embedded metals for stoplog gate shall be provided in the intake bay. Stoplog unit when not in use shall be supported on dogging latches provided near the top of the structure. The stoplog is vertical lift, slide type of fabricated steel construction and shall be formed by two vertical end girders between which horizontal girders are spaced according to design loads and the downstream face is covered with a skin plate. The stoplog is provided with two lifting lugs. Stoplog shall be provided seals on downstream side. Side seals shall be of rubber music note type and bottom seal of rubber wedge type. The seals shall be fastened to the stoplog unit using stainless steel bolts and nuts. Stoplog shall be provided with two guide shoes on each side. The stoplog shall be handled by a monorail hoist using a lifting beam capable of grappling and ungrappling of stoplog unit under water. The lifting beam shall be attached to the hoist at two points. Two filling valves of 150 mm dia. shall be provided in the stoplog for creating balanced head conditions. Fabricated steel frames shall be provided in the weir bays to receive the stoplog. The frames shall consist of side and bottom seal seats, tracks i.e. load carrying faces to bear the thrust pads fixed on the stoplog units and guides on both ides. Faces of seal seats and tracks shall be of corrosion resisting steel. The Mono-rail Hoist shall be installed on steel structure above stoplog grooves. Electric power will be provided through a trailing cable and reeling drum arrangement. Necessary brakes, overload protection, interlocks etc. shall be provided. All drive and hoist gears will be fully enclosed. Data i) Type of Stoplog gate : Vertical lift, slide with down stream skin plate and downstream seals, nonregulating type i.e. not to be kept at partial opening. : : :
7
ii) No. of Bay iii) No. of stoplog gate required iv) Clear width of opening
Part A
One One 3000 mm
v) Height of stoplog vi) C/C of side seal seats vii) C/C of Track Plates viii) C.L. of top seal seat (from sill) vi) Sill level vii) Reservoir Level viii) Top level of civil structure ix) Breast wall bottom level x) Design head
: : : : : : : : :
1400 mm 3150 mm 3500 mm 1500 mm 2449.50 m 2454.62 m 2456.50 m 2450.90 m 5.5m (Including 0.38 m free board) Rubber, music note. Rubber, wedge
xi) Type of side seals xii) xiii) Type of bottom seal
: :
Lowering / raising speed of hoist : 0.75 m/min to 1.5 m/min : : 4.0 m / min. to 8.0 m / min. Lowering / raising under balanced had conditions by Mon-rail Hoist. : M-30 Min.
xiv) Travelling speed of hoist xv) Operation
xvi) Second stage concrete in block-outs xvii) Permissible stresses 1.5 :
Dry & Accessible, IS: 5620
INTAKE TRASHRACKS
The trash racks shall be required to be installed in the inclined grooves of Intake structure U/S of stop log groove to prevent entry of extraneous material into the power house. These shall be of fabricated steel construction consisting of trash bars supported on horizontal bars, which in turn shall be supported on end channels/members to bear against the downstream face of slots. Trash racks shall be split into units of equal height for easy handling. The units shall be interchangeable and each unit shall have two lifting points. The trash racks units shall be handled by Mono-rail Hoist using a lifting beam capable of grappling/ ungrappling under water. The lifting beam shall also travel in the same groove as the trash racks. Cleaning of trash racks shall be done manually. Alignment pins shall
Part A 8
be provided between consecutive units of the trash racks for their alignment during placement. Height of trash racks is kept such that its top is above Reservoir Level El. 2452.62 Data Clear width of opening No. of openings Sill level Reservoir Level Top of structure Top of trash rack Clear spacing between trash bars Thickness of Trash Bars Differential head for design : : : : : : : : : 3500 mm Three El. 2449.50 m El. 2454.62 m El. 2456.50 m El. 2455.50 m 75 mm 12 mm 1.5 m One set.
No. of sets of trash racks required. : more than 3 units. Operation :
Lowering / raising by Mon-rail Hoist. M-30 Min.
Second stage concrete in block-outs: Design standard 1.6 :
IS: 11388
DESILTING GATE OF DESANDER
Provision to close the bays of the Desilting Basin bays by gates has been made to facilitate repair and maintenance of one bay at a time. For this purpose gate grooves have been provided in all the bays at the d/s end & u/s end of the Desilting Basin. The gates shall be lowered when water level in the reservoir is at Reservoir Level or below it. Inspection, maintenance and repairs of Desilting Basin shall be planned to be started and completed in lean flow period. The water level in the reservoir shall remain at Reservoir Level or below it, as long as the gates are in position and these shall be removed before water level in the reservoir rises above Reservoir Level. The gates shall be lowered/raised under balanced head conditions only i.e. under no flow conditions. Balanced head conditions shall be obtained by
Part A 9
crack opening of the gate. The gate shall be capable of self closing i.e. by gravity under its own weight. The gates shall be handled by a mono-rail hoist of suitable capacity using a Lifting Beam capable of grappling / in -grappling of gate under water. Embedded metals for gates shall be provided in all the bays at d/s & u/s ends. The gates when not in use shall be supported on dogging latches provided near the top of the civil structure. The gate is vertical lift, fixed wheel type and having skin plate & seals on the upstream side designed to withstand full static head corresponding to Reservoir Level as indicated in the data given hereafter. The lowering/raising of gate shall be under balanced head conditions only and therefore this shall be capable of gravity closing (i.e. due to weight of gate) under these conditions. The gates shall normally remain open and shall be closed when cleaning of Desilting Basin is required to be done. The gate shall be of fabricated steel construction consisting of upstream skin plate, horizontal girders and vertical stiffeners spaced according to design loads, end vertical girders and wheel assemblies mounted in between end vertical girders. The gate shall have two lifting points and shall be provided with seals on upstream sides. Side seals shall be of cladded rubber music note type and bottom seal shall be of rubber wedge type. The seals shall be fastened to gate using stainless steel bolts/counter sunk screws and nuts. To limit the sway of the gate during operation two guide shoes shall be provided on each side of the gate, which will remain engaged with embedded guides. The gate operates within fabricated steel gate frames embedded in concrete. The gate frame consists of wheel tracks (base of structural steel and track of corrosion resisting steel); side and bottom seal seats (Base of structural steel and faces of corrosion resisting steel) and structural steel guides. Data i) Type of Gate : Fixed wheel with upstream skin plate and upstream seals, regulating type i.e. may be kept at partial opening. : : : :
10
ii) No. of Openings iii) No. of gates iv) Clear width of opening v) Height of gate
Part A
Two Two 4900 mm 2451.00 ( _ ) 2449.20 ( + ) 0.2 free board
= 1.8 + 0.20 m = 2000 mm vi) C/C of side seal seats vii) C/C of Track Plates vi) Sill level vii) Reservoir viii) Design head : : : : : 5050 mm 5400 mm 2449.20 m 2451.00 m 2.0m (Including 0.2 free board) 2452.00 m
ix) Level of Top of Structure
x) Type of Wheel Assembly : Wheel mounted on corrosion resisting steel axle with roller bearings and having line contact with track. xi) Type of side seals : Rubber, music note Teflon cladded xii) Type of bottom seal : Rubber, wedge
xiii) Lowering / raising speed of hoist : 0.75 m/min to 1.5 m/min xiv) Traveling speed of hoist xv) Operation : : 4.0 m / min. to 8.0 m / min. Lowering / raising under balanced had conditions by Mon-rail Hoist. : M-30 Min. Wet & Accessible, IS:4622
xvi) Second stage concrete in block-outs xvi) Permissible Stresses 1.7 :
HRT INTAKE TRASHRACKS
The trashracks shall be required to be installed in the grooves of HRT Intake structure U/S of stoplog groove to prevent entry of extraneous material into the power house. These shall be of fabricated steel construction consisting of trashbars supported on horizontal bars, which in turn shall be supported on end channels/members to bear against the downstream face of slots. Trashracks shall be split into units of equal height for easy handling. The units shall be interchangeable and each unit shall have two lifting points. The trashracks units shall be handled by Mono-rail Hoist using a lifting beam capable of grappling/ungrappling under water. The lifting beam shall also travel in the same groove as the trashracks. Cleaning of trashracks shall be done manually. Alignment pins shall be provided between consecutive units of the trashracks for their
Part A 11
alignment during placement. Height of trashracks is kept such that its top is above Reservoir Level El. 2449.50 Data Clear width of opening No. of openings Sill level Reservoir Level Top of structure Top of trash rack Clear spacing between trash bars Thickness of Trash Bars Differential head for design : : : : : : : : : 3700 mm One El. 2444.80 m El. 2449.5 m El. 2450.0 m El. 2449.50 m 75 mm 12 mm 1.5 m : One set.
No. of sets of trash racks required. more than 3 units. Operation Second stage concrete in block-outs Design Standards 1.8 DRAFT-TUBE GATE : :
Lowering / raising by Mon-rail Hoist. : M30 Min. IS: 11388
Provision to close the bays of the Draft-tubes by GATE has been made to facilitate repair and maintenance of one Draft-tube at a time. For this purpose gate grooves have been provided in at the Tail-race end of the Draft-tubes. The gate shall be lowered/raised under balanced head conditions i.e. under no flow conditions. The gate shall be capable of self closing i.e. by gravity under its own weight. Embedded metals for gate shall be provided at the Tail-race end of the Draft-tube. gate when not in use shall be supported on dogging latches provided near the top of the structure.
Part A
12
The gate is vertical lift, slide type of fabricated steel construction and shall be formed by two vertical end girders between which horizontal girders are spaced according to design loads and the downstream face is covered with a skin plate. The gate is provided with two lifting lugs, gate shall be provided seals on downstream side. Side seals shall be of rubber music note type and bottom seal of rubber wedge type. The seals shall be fastened to the stoplog unit using stainless steel bolts and nuts. Stoplog shall be provided with two guide shoes on each side. The stoplog shall be handled by a monorail hoist using a lifting beam capable of grappling and ungrappling of stoplog unit under water. The lifting beam shall be attached to the hoist at two points. Two filling valves of 150 mm dia. shall be provided in the stoplog for creating balanced head conditions. Fabricated steel frames shall be provided in the bays to receive the stoplog. The frames shall consist of side and bottom seal seats, tracks i.e. load carrying faces to bear the thrust pads fixed on the stoplog units and guides on both ides. Faces of seal seats and tracks shall be of corrosion resisting steel. The Mono-rail Hoist shall be installed on steel structure above stoplog grooves. Electric power will be provided through a trailing cable and reeling drum arrangement. Necessary brakes, overload protection, interlocks etc. shall be provided. All drive and hoist gears will be fully enclosed. Data i) Type of gate : Vertical lift, slide with down stream skin plate and downstream seals, non-regulating type i.e. not to be kept at partial opening. : : : : : : : : :
13
ii) No. of Bay iii) No. of gate required iv) Clear width of opening v) Height of gate vi) C/C of side seal seats vii) C/C of Track Plates viii) C.L. of top seal seat (from sill) ix) Sill level x) Max. Tail-race Level
Part A
Two. Two. 2200 mm 3400 mm 2350 mm 2700 mm 3500 mm 2378.00 m 2382.60 m
xi) Top of civil structure level xi) Bottom of Breast Wall xii) Design head
: : :
2385.00 m 2381.40 m 4.9m (Including 0.3 m free board) : : Rubber, music note (hollow). Rubber, wedge
xii) Type of side seals xiv) xiv) Type of bottom seal
Lowering / raising speed of hoist : 0.75 m/min to 1.5 m/min : : 4.0 m / min. to 8.0 m / min. Lowering / raising under balanced had conditions by Mon-rail Hoist. : M-30 Min.
xvi) Travelling speed of hoist xvii) Operation
xviii) Second stage concrete in block-outs xix) Permissible Stresses :
Dry & Accessible, IS: 5620
1.9 ROPE-DRUM HOISTS (For Weir Gates & Intake Gate) For each gate, one electrically operated mechanical hoist is proposed. The capacity of the hoist to meet the operation requirements as outlined in paras 1.1 & 1.3 and shall be worked out by contractor and shall be 20% more than all the forces opposing the raising of gate. The hoists shall raise or lower the gate at a speed of 50 cm/minute. The hoists shall be designed to conform to Indian Standards Specification IS: 6938 and other relevant IS: Specification or their corresponding International Standards. The hoists shall be installed on the hoist bridge as shown in the appended drawings. The hoists shall be capable to perform the operation of crack opening of the gate under maximum unbalanced head conditions and shall also take care of down pull, if any, in this operation. A clear walkway for the operating/maintenance personnel of 1.0 m width shall be provided on either side of the hoist. Normal operation of the hoists shall be by electric motors. Manual operation shall be provided for operation of the hoists in the event of electric supply failure. Manual operation system shall conform to Clause 6.7 of IS: 6938. The hoists and their components shall be simple in design and rugged in construction so as to give trouble free operation with minimum maintenance. These shall be suitable for out-door service. The driving unit shall comprise of an electric motor, electro magnetic brake, reduction unit, limit switches, electric control elements, necessary shafts, bearings and flexible couplings. The driven unit shall
Part A 14
comprise of two rope drums, reduction units, shafts, couplings and bearings. The electric motor, brakes, reduction unit and rope drums shall be provided with removable weather proof metal covers. The controls of the hoists shall be so arranged that the cycle for either closing or opening shall be completed and the hoist shall stop automatically at the fully closed or fully open position by the limit switches. Over travel limit switches shall also be provided in both directions of travel which shall trip the motor circuit when the normal limit switches fail to operate. It shall also be possible to stop the hoist in any intermediate position of any cycle and restart or reverse as desired during the normal operation. The control panels shall be installed near the gates on top of piers as outlined in paras 1.1& 1.3 above. The panels shall have three push buttons marked, open , close and stop . The open push button shall initiate raising of gate. The close push button shall initiate closing of gate. By pressing the stop push button the gate shall be stopped in any intermediate position. Indicating lamps shall be mounted on the control panels to know the position of gate. Blue and green lamps shall show that the gate is being lowered and raised respectively and these lamps shall go off automatically with the stoppage of gate movements. The red lamp shall show that he gate is in open position. The controls shall also fulfill the following requirements: A solenoid brake shall be provided to hold the gate in any position. It shall come into action automatically as soon as it is de-energized on cutting or failure of power supply to motor. Extreme position of gate shall be restricted by limit switches when the gate reaches the extreme positions, blue / green lamp is switched off and the solenoid brake applied automatically. The design of hoist mechanism shall be based on the gate opening / lowering speeds mentioned in the above paras. The gates shall fall under their own weight so as to effect closure of the bay, the only operation involved shall be to release the brakes. It shall be possible to accomplish this operation in any one of the following two ways. However during closing operation, the controls will come into play when the gate is about 150 mm above the sill ( i.e. the last 150 mm of the fall of gate ) to ensure smooth landing of the gate on the sill. (i) (ii) By pressing the push button on the panel to close position. By hand lever provided on the brake in case of failure of power.
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15
The controls and hoist drive equipment of a hoist shall consist of an electric motor with reversible contactors, main contactor, electro-magnetic brake, disconnection switch, push buttons, limit switches and other appurtenances etc. The control cabinets shall be of the frame mounting type having sufficient size so as to neatly and methodically accommodate all the electric, power and control equipment. The cabinets shall be of a repute make. Equipment such as indicating lamps, push buttons etc. shall be installed flush mounted on the door of the control cabinet so that the gate can be operated with the cabinet door closed. The remaining equipment shall be installed inside the cabinet, being accessible when the door is opened. The cabinets shall have access only at the front. The cabinets shall be suitable for outdoor use in tropical climate and shall be provided with suitable protection against ingress and moisture. 1.10 MONO-RAIL HOIST (For Weir & Intake Stoplogs, Intake Trashracks,Desilting Gates and Draft-tube Gates ) Electrically operated monorail hoist shall raise/lower stoplog gate units. The hoist shall traverse all bays of the Stoplog. Lowering/raising and traverse speed shall be as specified in paras 1.2, 1.4, 1.5, 1.6 & 1.7 above. The hoist capacity shall be adequate to meet the operation requirements and shall be 20% more than all the forces opposing the raising of a stoplog. The hoists shall be designed/manufactured to conform to Indian Standards Specifications IS: 3938 or their corresponding International Standards. The hoists shall be installed on the monorails supported on hoist structure as shown in the appended drawings. Mono-rail Hoist will consist of two electric motors (one for hoisting and the other for traversing mechanism), two independent electro-magnetic/thruster brakes, gear reduction units for both the motors (working independently), rope-drum, ropes, pendant switch, limit switches, main hoisting controls, PVC insulated cable for power supply and its mounting structure, other accessories etc. Electric interlocking shall also be provided to ensure that either raising / lowering operation or traverse motion is operative at a time. The hoists shall be suitable for outdoor service. Amber indicating lamp shall be provided on the pendant itself to indicate that the electric Supply is on .
Part A
16
Tender Documents Specification: Volume II B Hydro Mechanical Part A
SECTIQN 2 TECHNICAL SPECIFICATIONS AND REQUIREMENTS 2.0 GENERAL
The Hydro-mechanical equipment included in scope of work shall conform to the following basic requirements and specifications. 2.1 2.1.1 DESIGN & STRESS LEVELS GATES (DIVERSION WEIR UNDERSLUICE, INTAKE& SESILTING)
(a) Various components of the gates and embedded parts shall be designed in accordance with the provisions IS:4622 or its corresponding International Standard. The horizontal girders and wheels shall be so spaced that they carry equal load (approximately). (b) (i) Loads to be considered for design: The gate shall be designed for the hydrostatic head corresponding to Reservoir Level El. 2454.62 m and as indicated in Paras 1.1 & 1.3 in Section 1 of these specifications. The design of gates shall be checked for the combination of above design head and earthquake effect in accordance with IS 1893 Indian Standard Criteria for Earthquake Resistant Design of Structures or its corresponding International Standard. Allowable stresses in this case shall be increased by 33.3% subject to an upper limit of 85% of Y.P.
(ii)
2.1.2 STOPLOGS (DIVERSION WIER UNDERSLUICE, INTAKE & DRAFT-TUBE) (a) The stoplog for Diversion Weie Undersluice & Intake shall be designed for the hydrostatic head corresponding to Reservoir Level El. 2454.62. The D.T. Gate Stoplog shall be designed for head corresponding to Max. Tail Water Level El. 2382.60. b) Various components of stoplog gate and embedded parts shall be designed in accordance with the provisions of IS-5620 or its corresponding International Standard. (c) The design of stoplog shall be checked for the combination of above hydrostatic head and earthquake effect in accordance with IS: 1893 or its corresponding International Standard. Allowable stresses in this case shall be increased by 33.3% subject to an upper limit of 85% of Y.P.
Part A 17
2.1.3 INTAKE TRASHRACKS a) The trashracks shall be designed for a differential head of 1.5 m. b) Various components of trashracks shall be designed in accordance with the provisions of IS: 11388 or its corresponding International Standard. Permissible stresses shall be as per IS: 11388. 2.1.4 ROPE DRUM HOISTS
Various components of hoist such as wire rope, drums, sheaves/pulleys, gears and pinions, worm gear reducer, shafts, keys, bearings and coupling etc. and their design shall meet the requirements of IS:6938 and IS:800 or its corresponding International Standard. The worm gear reducer shall be a standard superior quality product of established/reputed manufacturer of such equipments. The openings in the housing of the reducer etc. shall be provided with dust proof seals/packing. All gears/pinions shall be enclosed in fabricated steel cases having air tight covers with windows at the top for inspection. The openings in the gear cases for shafts shall be provided with dust proof seals. The wire rope shall be ungalvanised of suitable construction having adequate diameter and shall conform to IS: 2266 or its corresponding International Standard. Bolts, buts and screws used shall conform to relevant Indian Standards. Bolts and screws in rotating parts shall be locked. Bolts in tension shall be avoided as far as possible. Wherever necessary net section of such bolts at the root shall be increased by 15%. Flexible coupling between the motor, worm gear, reducer shall permit both angular and off set misalignment between the coupled shafts. These shall be of the size rated for the shafts to which these are connected and shall have torque rating suitable for the loads transmitted. These shall be of flanged type fully enclosed and dust proof and shall conform to relevant clause of IS:6938 or its corresponding International Standard. 2.1.5 MONO-RAIL HOISTS (For Stoplog gate)
Various components of these equipment shall be designed in accordance with provisions of IS: 3177, IS: 6938 and IS: 807. Capacities of these shall be125 percent of all the forces opposing the hoisting with loads intended to be handled. These equipments shall be of class 2 classification as per IS: 807. Corresponding International Standards for the above Standards may also be followed.
2.1.6
Part A
LIFTING BEAMS
18
The lifting beam for stoplog gate and trashracks shall be designed in accordance with provisions of IS: 13591 or its corresponding International Standard. 2.1.7 Bought-out Items
All bought out items shall be of the best available make and shall be the product of manufacturers of repute bearing standardization marks. 2.2 PERMISSIBLE STRESSES
GATES (Diversion Weir Under sluice & Intake) The permissible stresses shall be taken those corresponding to wet inaccessible conditions as per Annex. B of IS: 4622-2003 or its corresponding International Standard and are given as under: Material and Type of Stress Structural Steel Wet & Accessible condition (i) Direct Compression/tension (ii) Compression/tension in bending (iii)Shear (iv)Combined (v) Bearing Concrete M-30 (In Block-outs) (i) Bearing (ii) Shear 0.25 fck 76.50 kg/sq.cm 4.0 kg/sq.cm 0.45 Y.P. 0.45Y.P. 0.35 Y.P. 0.55 Y.P. 0.45 Y.P. Permissible Stress
DESILTING GATES The permissible stresses shall be taken those corresponding to dry accessible conditions as per Annex. B of IS:4622-2003 or its corresponding International Standard and are given as under: Material and Type of Stress Permissible Stress
Structural Steel Wet & Accessible condition (i) Direct Compression/tension (ii) Compression/tension in bending (iii)Shear
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0.45 Y.P. 0.45 Y.P. 0.35 Y.P.
(iv)Combined (v) Bearing Concrete M-30 (In Block-outs) (i) Bearing (ii) Shear 2.2.3
0.55 Y.P. 0.45Y.P.
76.50 kg/sq.cm 4.0 kg/sq.cm
STOPLOGS (diversion Weir Undersluice, Intake & Dtaft-tube)
As these are stored above water level and are only occasionally used, permissible stresses have been taken those corresponding to Dry-accessible conditions as given in Appendix B of IS:5620 or its corresponding International Standard. Material and Type of Stress Permissible Stress
Structural Steel Dry & Accessible conditions (i) Direct Compression/tension (ii) Compression/tension in bending (iii)Shear (iv)Combined (v) Bearing Bearing Stress Bronze on Steel 0.55 Y.P. 0.55 Y.P. 0.4 Y.P. 0.75 Y.P. 0.75 Y.P. 0.04 U.T.S.
Concrete M-30 (In Block-out) (i) (ii) 2.3 2.4 Bearing Shear DELETED MATERIALS 7650 kg/sq.cm 4.0 kg/sq.cm
All materials incorporated in the equipment shall be new, unused and of first class quality, free from defects and in accordance with relevant Indian Standard (Latest revisions) or their corresponding International Standards. Materials and Proprietary items shall be selected taking into consideration customary use for type and class of equipment having regard to strength, the durability and best engineering practice. As a general guidance materials used for various items of gates and hoists are given as under: In the Tables for Materials only the Indian Standards have been indicated. Corresponding International Standards can also be followed.
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2.4.1 GATES (Diversion Wier Undersluice, Intake & Desilting ) _______________________________________________________ S.No. Component Part Material Material Specs. (Latest) (i) Structural parts of gates Structural i.e. skin plate, horizontal girders, end vertical girders, Vertical stiffeners,seal bases, seal clamps, guide shoes, etc. Wheel track bases, seal seat , Structural bases, Sill beam base, guides, Steel . anchor bolts etc Wheels Wheel Axle Pin Cast Steel IS: 2062
(ii)
IS: 2062
(iii) (iv)
IS: 1030
Corrosion Resistant 20 Cr 13 Steel IS: 1570 Part IV Spherical roller Bearing SKFmake or equivalent
(v)
Wheal Bearings
(vi)
Music Note type IS: 11855 44 mm dia (Hollow) (Plain rubber for Barrage & Barrage Under Sluice Gates and Teflon cladded for Head Regulator Gate). (b) Bottom Rubber Wedge Type IS: 11855
Seals
(a) Side
(vii)
Wheel track and Seal Seats Corrosion Resistant 30 Cr 13 for Track Steel 04 Cr 18 Ni 10 for seal seat IS:1570 Part IV 2.4.2 STOPLOGS (Diversion Weir Undersluice, Intake & Draft-tube) __________________________________________________________________ S.No. Component Part Material Material Specs. (Latest) __________________________________________________________________ (i) Structural parts of stoplogs Structural IS:2062/ i.e. skin plate, horizontal Steel girders, end vertical girders, vertical stiffeners, seal bases, seal clamps, guide shoes, etc.
21
Part A
(ii)
Track bases, seal seat bases, Structural Sill base, guides, anchor bolts Steel etc Tracks, seal seats Corrosion Resistant Steel Rubber - music note type 44 mm dia (Hollow) Rubber Wedge Type
IS: 2062.
(iii)
04 Cr 18 Ni 10 IS: 1570 Part IV IS: 11855
iv)
Seals (a) Side
(b) Bottom (v) Thrust Pad
IS: 11855 IS: 2062
Structural Steel Cladded with Bronze (Min.10 mm thick) IS: 305
2.4.3
INTAKE TRASHRACKS
Materials for various components of trashracks shall be Structural Steel conforming to IS: 2062. 2.4.4 ROPE-DRUM HOISTS, MONO-RAIL HOISTS Materials for various components of the equipments shall conform to provisions of IS: 807, IS: 3938 and IS: 6938 or their corresponding International Standards.. 2.5 EMBEDDED FRAMES FOR GUIDES AND WHEEL PATHS
Wheel paths, seal path and guide tracks shall be provided up to following heights: Guide Tracks Wheel Paths : : Full range of gate/stoplog travel Fixed Wheel Gates --- up to twice the gate height Stoplogs-gate height plus 0.5 m Sill level to one gate height or up to lintel seal.
Seal Paths
For installations of embedded parts in 1ststage blockout, suitable and adequate number of anchor bolds welded to first stage anchor plate shall be provided to align and level embedded parts and retain them during concreting. Necessary stainless steel sealing faces and corrosion resistant roller paths machined accordingly shall be provided. The spacing of first stage embedded parts (anchor plate) shall be not more than 500 mm. 2.6
Part A
ELECTRICAL EQUIPMENT
22
The electric motors furnished shall be suitable for operation on 415. volts. 3 phase, 50 cycles A.C. supply. The motors shall be squirrel cage, reversing type with high starting torque characteristics and shall conform to Indian Standard IS:325 or its corresponding International Standard. The motors shall be totally enclosed fan cooled an d suitable for outdoor use in tropical climate and highly humid atmosphere. The rated sped of the motor shall not be more than 1000 r. p m. The electric motors shall be designed having starting current kept as low as practicable consistent with good design. The motor shall be suitable for frequent start, stop operation. The winding insulation shall be class 'F' and the entire coil, system shall be completely void free and impregnated with an impervious epoxy resin forming a completely solid integrated insulation structure. The entire insulation system shall be moisture free type, mechanically stable, abrasion resistant and sufficiently resilient to withstand effects of thermo cycling without developing defects throughout the life of the electric motor. The maximum temperature rise of the winding when the electric motor is delivering rated output continuously at rated voltage and frequency shall not exceed 40"C (1040 F) above ambient temperature at project site. The temperature rise of other parts of the motor shall be in accordance with the Indian Standards. The electric motors shall be equipped with either ball or roller type self lubricating bearings which shall be properly sealed against loss of lubricant or entrance of dust. To prevent condensation, the electric motors shall be equipped with 240 volt single phase anti-condensation heater mounted in or on the frame. The leads of the electric motor and the heater shall be brought out in a terminal box on the motor having suitable cable entry lugs. For isolating the electric motors from the supply system manually operated triple pole disconnecting switch of suitable capacity shall be installed in the cabinet. The disconnecting switch shall conform to IS:2607 Air break isolator for voltage not exceeding 1 000 volts or its corresponding International Standard and shall be suitable for operation on 41 5 volts. For the electric motors, following contactors of suitable capacity shall be provided. Two phase Raise contactors Two phase Lower contactors Three phase Main contactors
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23
The contactors, shall be direct on the line starting air break type and suitable for operating on 415 volts, 3 phase, 50 cycles A.C. supply. The contactors shall conform to IS: 1822, "AC motor Starters of voltage not exceeding 1000 volts" and IS: 2959 "A.C. Motor contactors of voltage not exceeding 1000 volts". Corresponding International Standards may also be followed. H.R.C. fuses of suitable capacity shall be provided in the main power circuit and control and heater circuit for protection against short circuits. Limit switches, provided for normal stopping of the gate at extreme position of travel, shall reset automatically on reversing the direction. Over travel limit switches shall be provided to take care if normal limit switches fail to operate or the raise flower contactor fails to open. These limit switches shall also be capable of being reset by reversing the direction of travel or pressing the 'Reset' push button. The limit switch shall be of totally enclosed type. The cables shall be P.V.C. insulated, P.V.C. sheathed conforming to IS:694 'P.V.C. insulated cables for voltage up to 1000 V'. Consideration shall also be given to such factors as ambient temp. grouping and disposition of cables and to the limitation of voltage drop while selecting the cables. The cables from the power and control cabinet to the various equipment shall also be supplied by the contractor. Power cables shall not be less than 4 sq.mm nominal copper area. The conduits and conduit fittings shall be heavy gauge galvanised steel conforming to IS: 1653 "Rigid at Steel Conduits for Electrical Wiring", and IS: 2667 'Fitting for rigid steel conduits for electrical wiring". -Flexible conduit may also be used wherever required. 2.7 SHOP ASSEMBLY & TESTING
All equipment fabrications and structures covered by the specifications shall be fully assembled in Manufacturer's shop for inspection by Engineer to the extent necessary to demonstrate matching of structural components. All necessary adjustments shall be made in the shop to achieve the specified tolerances. Checks on dimensions and tolerances shall be recorded by Manufacturer and three (3) copies furnished to Engineer within a week of shipment of the material. Without limiting the foregoing. the following shop assemblies shall be carried out. The gate components such as - Wheel assemblies (in case of fixed wheel type gates); - The electrical control panels, starter, contactors, position indicators etc. Prior to dismantling, each assembly shall be permanently and clearly match marked in the shop to facilitate site erection. Dismantling shall be done only to the
Part A 24
point required for shipping. In particular. there shall be minimum disconnection of electrical wiring. Engineer will inspect all equipment during fabrication and before shipment and witness the shop tests after final assembly. 2.7.1 Gate Frames
The metal work shall be shop assembled to the extent necessary to ensure that all parts are properly fitted and that the dimensional and tolerance requirements shown on the drawings have been obtained. All holes for field connections of parts furnished under these specifications shall be drilled or reamed as noted on the drawings, with the embodiments so assembled. Members to be shop-riveted shall have all parts well pinned up and drawn together with bolts before riveting is commenced. 2.7.2 Gates
Each component of gate and stoplog shall be assembled in the shop to the extent necessary for inspection and to ensure that all parts fit properly and that dimensions. clearance and tolerances required in the specifications and drawing have been achieved. Holes for field connections shall be carefully drilled or reamed. Connections which have to be disassembled for shipment shall be made by the use of erection pins, one size less in diameter than the designed size or temporary machine bolts. Proper functioning/operation of filling in valve and lifting beam, automatic engaging/disengaging shall be checked during shop assembly. 2.7.3 Hoists
All electrical and mechanical components shall be tested in accordance with the appropriate Indian Standards at either the Maker's or equipment manufacturers works and tests certificate provided. The hoist shall be assembled in the shop to the extent necessary to ensure that all parts are properly fitted. Surfaces of metal which will be in contact shall be cleaned before the parts are assembled. The parts shall be adjusted to line and fit and shall be well pinned and bolted so that the surfaces are in close contact before reaming, drilling, rivetting or welding is commenced. Drifting done during assembly shall be only that is necessary to bring the parts into position and not so much as to enlarge the holes or distort the member, if any, hole must be enlarged to admit fastening, it shall be reamed. The field connections shall be fitted and checked in the shop to assure proper fit during field erection.
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25
After shop assembly the hoist shall be tested at manufacturer's works in accordance with relevant Standards. The manufacturer shall supply all material equipment and labour required for shop assembly and tests. and cost thereof shall be included in the bid price. All shop tests shall be made in the presence of the Engineer or his representative. The hoist shall be prepared for shipment in as large units as practicable. One print of a diagram of match marks shall be enclosed with the shipment and four prints shall be forwarded to the Engineer. 2.7.4 Place of Manufacture and Inspection The contractor shall intimate the place of manufacturer, testing and inspection of the various portions of the work. Authorised representative of the Purchaser may be present at the time of any or all tests and the Manufacturer shall provide all necessary facilities for the same. Representatives of the Purchaser shall also be entitled to access to Manufacturer's sub-contractors work at any time during the working hours for the purpose of inspecting the manufacture of equipment and materials. To satisfy himself that the materials and equipment comply with the conditions of contract, the Engineer-in-Charge of the Purchaser reserves to himself the right of having at his expense, any inspection or tests of a reasonable nature carried out in addition to the routine tests specified in the appropriate Indian Standards. 2.7.5 Inspection
All materials furnished shall be of tested quality and all work performed shall be subject to rigid inspection and no articles or materials or supplies shall be despatched until all tests. analysis and shop inspection have been completed or certified copies of reports or results of tests and analysis shall have been accepted. Duplicate copies of manufacturers test certificate shall be submitted to the Engineer in Charge of the Purchaser as soon as the tests are completed. In case tests certificate are not available for any of the materials, the same may be got tested and only those materials which fulfil the requirements of the specifications shall be used. From any part/item, it should be possible to locate its manufacturer Batch/Lot mark, which shall be achieved by transferring the batch mark before parting the materials. All supplies (which include without limitation raw materials. components. intermediate assemblies and assemblies and end products) shall be subject to inspection and test by the Purchaser to the extent practicable at all times and places. If any inspection or test is made by the Purchaser in the premises of the Manufacturer or subcontractor, the Manufacturer without additional charge shall provide all reasonable facilities and assistance and the safety and convenience of
Part A 26
inspectors in the performance of their duties. If on the request of the Purchaser, inspection or test is made at a point other than the premises of the Manufacturer or sub-contractor of the Manufacturer, it shall beat the expense of the Purchaser except as otherwise provided in the contract, provided that in case of rejection, the Purchaser shall not be liable for such expenses. 2.8 2.8.1 SITE TESTING & COMMISSIONING Operational Tests
(a) The Manufacturer shall carry out in the presence of Purchaser such tests on the equipment to determine that the same will fulfil the functions for which they have been designed. The tests shall be carried out in accordance with provisions of IS: 7718. Tests shall be repeated, if necessary, until successfully carried out to the satisfaction of the Purchaser. leakage tests and operational tests shall be carried out after completion of other portions of the work and when the reservoir is at full reservoir level. Purchaser shall have the right to carry out such tests also when reservoir is at a level other than full reservoir level. (b) (1) For hoists the following tests shall be carried at site after erection. Insulation tests:
After erection but before the hoist is connected to the supply. the insulation of the electrical equipment shall be tested by a suitable instrument and any defects revealed shall be rectified. The voltage required for the insulation resistance test shall be d.c. voltage not less than twice the rated voltage. i) Any reading less than 0.5 mega ohm obtained with an insulation resistance tester of the unregulated type shall be disregarded and the wiring under test shall be sub-divided until a reading higher than 0.5 mega ohm is obtained. Failure to obtain a higher reading shows an unsatisfactory state of insulation. If an installation has been sub-divided for test purpose. each sub-division shall meet the requirements. ii) The insulation resistance of each wiring circuit exclusive of connected apparatus shall be not less than 2 mega ohms. If necessary, it shall be permissible to disconnect individual items of equipment while making this test. (2) Test for operation:
After the supply has been connected and before the complete hoist installation is put to commercial service, tests shall be carried out to prove the following:
Part A
27
i) The satisfactory operation of each controller, switch, contactor, relay and other control devices and in particular the correct operation of all limit switches under the most unfavourable conditions. ii) The correctness of all circuits and interlocks and sequences of operation. Satisfactory operation of all protective devices. iv) The satisfactory operation of each motion of the hoist. v) The compliance of the hoist with the specified performance requirements. vi) Tolerances on specified speed on full load shall be within 10%. (3) Deflection tests
The deflection test shall be carried out with the safe working load at rest. The measurement shall not be taken on the first application of the load. (4) Overload tests
After the above tests but before the hoist is put into service, it shall, with overload relays appropriately set, be tested to lift and sustain a minimum test load of 125 percent of the working load. 2.8.2 Dry Test
Operational tests in dry shall be carried out as soon as possible after completion of erection and all controls and permanent power supply have been connected. The tests shall include at-least two complete traverses from the maximum raised position to the full sealing position. All adjustments, clearances, brakes etc. shall be checked for proper and smooth operation. 2.8.3 Wet Test
These tests should simulate the actual operating conditions as closely as possible. At-least two complete traverses will be made from the fully closed position to the fully raised position as follows: a) When gate is closed, raise gate to its fully open position in steps and observe the performance including vibration. b) Lower the gate to the full closed position in steps and observe the performance of the gate vibration. c) Check up operation of limit switches.
Part A 28
2.8.4
Leakage Tests
Leakage tests shall be carried out with the gate resting on to the sill. Before measuring the leakage the gate shall be raised and lowered several times by about 20 to 40 cms or so in order to dislodge any debris that may have lodged in the side seal seat. The leakage shall then be measured and recorded. The maximum leakage past the seals shall not be more than 15 liters per min. per meter length of seal under maximum head conditions. 2.8.5 Final Acceptance
Final acceptance of the equipment shall be based on the following: a) Quality and workmanship of the equipment including dimensional accuracy. b) Satisfactory operation of the equipment after erection as required under these specifications. c) Acceptance of various tests or test certificates by the Purchase. All tests may be witnessed by the Manufacturer or his authorised representative. On successful completion of all tests the equipment shall be accepted but all the responsibilities shall remain with the Manufacturer within the guarantee period. The labour and material for the field tests shall be provided by the Contractor. The test load and necessary lifting tackles shall be provided by the Purchaser and Contractor respectively. 2.8.6 Guarantee
Within one year after issue of Certificate of Completion if any part of the gates, embedded parts, hoists etc. are found defective because of workmanship or material or otherwise. the Manufacturer shall, at his own expense furnish and install new parts and materials approved by the Purchaser. 2.9 WELDING PROCEDURE
2.9.1 The edges of plates and shapes to be joined by welding shall be properly formed to suit the type of welding selected. Where plates and shapes have been sheared. edges to be joined by welding shall be machined or chipped to sound metal. Plates and shapes to be field welded shall have their edges prepared in the shop for the type of weld selected.
Part A
29
Where bending or forming of plates or shapes is required, the plates or shapes shall be bent by cold forming. Heating and hammering to correct bends will not be permitted. 2.9.2 Welding
(a) Members to be joined by welding shall be cut accurately to size, and where required, shall be rolled or pressed to proper curvature in accordance with the approved drawings. The dimensions and shape of edges to be joined shall be such as to allow thorough fusion and complete penetration and plates shall be planned, if necessary, to accomplish this result. Members to be welded together shall be in sufficiently intimate contact at the time of welding so that members will
(b) not be forced more closely together with the cooling of the weld, thus setting up additional strains and distortions in the weld and parent metal. The surfaces of plates to be welded shall be free from rust, grease and scale for a distance of 12 mm back from the welding edge at the time of welding. Flame cutting may be used in the preparation of the various members provided the operation is performed carefully, and the edges so cut are cleaned thoroughly after being cut so as to expose clean metal. Any contour irregularities at points of critical stress shall be removed by grinding. (c) Welding Technique Care shall be taken in designs that the welds when being made, are well accessible. Overhead welding is to be avoided. if possible and flat position welding is to be strived for. Drawings should clearly indicate the joint position, or field welding, kind of welding, method of welding, welding sizes and other required information/data. Symbols to be shown on the drawing would conform to relevant lndian Standards. All welding shall be done by the electric arc method by a process which will exclude the atmosphere from the molten metal, except where otherwise specifically permitted. All welding electrodes required shall be furnished by the contractor. Correct selection of electrodes shall be done taking due care of welding method and base metals of components to be welded. The welding electrodes shall be of heavily coated type designed for all position welding. The make, type and size of all welding electrodes shall be subjected to the approval of the purchaser. In assembling and during welding the component parts of built up members shall be held in place by sufficient clamps or other adequate means to keep all parts in proper alignment and position. Radiographic tests shall be carried out for all critical full strength butt welds. i) Butt joints In principle, butt joints shall be made with back-run. Backing strap should be laced and welding should be so made that the molten metal fully penetrates and a full penetration is achieved. Dye-penetration test shall be carried out after each pass of
Part A 30
the weld. Radiographic testing of butt welds shall be carried out to the extent required by the Purchaser. ii) Fillet Joints All fillet welds shall be continuous. For the main member, no fillet welding should be made on members whose thickness differs substantially. Fillet weld at T Joints should be made, as a rule, on each side of the joint unless it is otherwise agreed due to some practical reasons. Radiographic test is not normally required for fillet welds. All the fillet welds shall be checked by Dye Penetrant Test by the Manufacturer in the shop. However 20% to 30% of fillet welds shall be checked by dye-penetrant test in presence of Purchaser to check soundness of weld. At Welded butt joints, where the weld material is required to be deposited on both sides of the joints, the weld shall be chipped or melted to obtain a clean surface prior the application of the first head of the welding on the opposite side of the joint. Where fillet welds are used, the lapsed sections shall fit closely and shad be held together during the welding operation. When weld metal is posited in two or more layers, each layer shall be brushed with a wire brush or otherwise cleaned before subsequent layer is deposited. In welding, precautions shall be taken to minimise stresses due to expansion or contraction either by peening the welds while hot, or by other satisfactory methods and also by using the proper sequence in welding. Correction of distortion by blows after welding is completed and the place is cold, will not be permitted. Upon completion, the welds shall be brushed with wire brushes and shall show uniform section, smoothness of weld metal, feather edges without excessive overlaps and freedom from porosity and clinkers. Visual inspection at edges and ends of fillets and butt joints welds shall indicate good fusion and penetration into base metals. (d) Welding Process
A specification of the welding process, that is proposed to be used. shall be established and recorded and if required, a copy of such specification together with a certified copy of report for results of tests made in accordance with the process and specifications shall be furnished. The qualification of the welding process shall be at least equal to that required by 'Standard Qualification Procedure' of the Indian Standards and the minimum requirement of the tests shall be atleast as stated in the said 'Standard Qualification Procedure': (e) Qualification of Welders
The Manufacturer shall be responsible for the quality of the work performed by his welding staff. All welders assigned to the work shall have passed qualification tests for welders. If at any time the work of any welder appears questionable, welder shall be required to pass additional qualification tests to determine his ability to perform the type of work on which he is engaged.
Part A 31
2.10
NON-DESTRUCTIVE TEST/ INSPECTION
In addition to and notwithstanding any requirements covered in previous clauses, Manufacturer shall perform adequate inspection and quality control and conform to the inspection procedures outlined below. All material entering into the work shall be subject to inspection by Engineer and all purchase orders for materials and supplies shall carry a notation to this effect. Copies of all purchase orders and subcontracts shall be submitted to Engineer at the time of placing the order. Waiving-off Inspection by Engineer shall not relieve the Manufacturer from the responsibility of supplying material and workmanship acceptable to Engineer. Manufacturer shall be responsible for proving quality of material and workmanship, either by record of inspection or by immediate inspection. Manufacturer shall perform any non-destructive testing and inspection required by Engineer on any material or workmanship in which defects are suspect. Witness tests and inspection of material will be made at the place of manufacture by Engineer. Engineer shall at all times have access to all places of manufacturer where equipment or materials are being made or prepared for use under this Contact and shall have full facilities, including office space and communication facilities, for unrestricted inspection of such materials and equipment. Whereas such witnessing and inspection will be conducted so as to interfere as little as possible with the operation of manufacture, Manufacturer shall conform to the requests made by Engineer, concerning the method of test or correction of defective workmanship. Unless otherwise specified, any rejection based on witness tests or general inspection will be reported to the Manufacturer within 10 days. Material which shows injurious defects subsequent to its acceptance at the Manufacturer's works. will be rejected and the Manufacturer shall be notified. Test pieces which represent rejected material shall be preserved for a period of time to be mutually agreed upon between Engineer and Manufacturer and Manufacturer may make claim for a reheating. Magnetic particle inspection shall be conducted in accordance with relevant codes. Radiography on welds for pressure containing parts, including the standard of acceptability, shall be performed according to relevant Boiler and Pressure Vessel Code. Radiographic testing of welds on structural steel, including the standards of acceptability, shall be performed in accordance with relevant Codes. All radiographic examination of shop and field welds shall be done by the Manufacturer. All field labour and access to equipment required for field radiographic examination shall be provided by the Manufacturer. All welds on
Part A 32
hydraulic cylinders shall be 100% radiographed. Ultrasonic examination of welds shall also be carried out. All unacceptable defects in welds shall be chipped out to sound metal and such areas shall be checked by magnetic particle inspection, radiographic or ultrasonic testing by the Manufacturer, as directed by the Engineer, to ensure that the defect has been completely removed before re-welding. Hundred (100) percent of the butt welds and T. Joints in load carrying members shall be radiographically tested. All testing of weldments shall be performed by Manufacturer at his expense. Radiograph and magnetic particle inspection of weldments shall be performed by manufacturer on all high stress carrying members. Manufacturer shall show the extent and location of weldment inspection on his drawings submitted to Engineer for review. Manufacturer shall arrange his fabrication program to permit inspection to be carried out in the following manner. Minimum Requirements for Non-destructive Testing Type of Weld Butt welds Manual and semiautomatic fillet welds Fully automatic Fillet welds Type of Inspection Radiographic Magnetic particle Extent of Inspection 100 percent 10 percent
Magnetic particle
500 mm at start and stop. 10% throughout the remainder.
Where welds are subject to radiographic examination, the technique to be used and the standards of acceptability of the welds shall be in accordance with relevant Codes. All defects in welds beyond the limits shall be removed to sound metal and such areas shall be magnetic particle inspected to determine that the defect has been completely removed before repair welding will be permitted. Repair welding shall be performed using a qualified procedure and in a manner acceptable to Engineer. Rewelded joints and weld-repaired areas shall be radiographically examined. 2.11
Part A
SURFACE PREPARATION & PAINTING

33
2.11.1
General
a) The Manufacturer shall provide as part of his supply the surface treatment, priming, corrosion protection and painting of the equipment furnished. Such work shall include the coating and painting work at the workshop and at the site up to and including the finish painting. Unless otherwise specified the coating and painting shall be carried out in accordance with provisions of IS: 14177 or its corresponding International Standard. All paints, painting material and accessories for painting shall be included in the price bid. All finished and unfinished surfaces of metal work (other than of aluminum brass, bronze or stainless steel)- except screw threads, mating surfaces, sliding surfaces, rolling surfaces shall be cleaned and protective coatings applied as specified in the above mentioned Standard. As a general guidance following is given. b) All paints and painting material shall satisfactorily fulfill the requirements imposed by the site conditions, as well as the stresses to which the respective equipment is subjected during operation of the works. Shades of the finishing coatings shall be as approved by the Purchaser or his representative. c) The paints and shades of the finished coatings proposed by the Manufacturer must be got approved by the Purchaser before application of the same. The analysis in respect of paint properties, paint composition and performance requirements of the paints shall be submitted by the Manufacturer for check and approval. All painting material shall conform to relevant Indian Standards. Each coat of printer and paint shall be compatible with the previous and subsequent coats. All pigmented primers and paints which will be used for priming and painting at the site shall be delivered in original and sealed containers packed by the manufacturer. e) The Manufacturer shall supply full details regarding the extent to which sandblasting, priming and painting will be carried out in his workshops (or his subcontractors, as the case may be) at the site and after erection. A properly equipped paint shop shall be set up at the site using a specialist organisation, experienced and skilled in the preparation and application of protective coatings at the conditions prevailing at the site. 2.11.2 Surface Preparation
After the equipment has been fabricated, it is essential that before any primer and coat of paint is applied, the surface is properly prepared. Such preparation shall include through cleaning, smoothing, drying and similar operation that may be required to ensured that the primer and/or paint is applied on suitable surfaces. Clean cloths and clean fluids shall be used to avoid greasy film or greasy residueon the surfaces being cleaned. The procedure for surface preparation shall be as follows:
Part A 34
a) Weld spatters or any other surface irregularities shall be removed by any suitable means before cleaning. b) All oil grease and dirt shall be removed from the surface by the use of clean mineral spirits, xylol or white gasoline (lad free) and clean wiping materials. c) Following the solvent cleaning, the surfaces, to be painted shall be cleaned of all rust, mill scale, and other tightly adhering objectionable substances by sand blasting or grit blasting to uniform bright base metal. Average surface roughness for sand blasted area shall not exceed 40 microns. Any grit or dust remaining after the cleaning operation shall be completely removed from the surface by wire brushing; air blowing, suction or other effective means before the surface is painted. d) Surfaces of stainless steel, nickel, bronze and machined surface adjacent to metal work being cleaned or painted shall be protected by masking tape or by other suitable means during the cleaning and painting operations. e) Primers shall be applied as soon as the surface preparation is complete and prior to be development of surface rusting. In case there is considerable time gap, the surface shall be recleaned prior to priming. 2.11.3 Shop Painting
a) Stainless steel and bronze surfaces shall only be cleaned but not painted. b) All surfaces of the embedded parts which are to come in contact with concrete shall be cleaned as mentioned above and given two coats of cement latex to prevent rusting during shipment and while awaiting installation. c) Two coats of zinc rich primer with epoxy resin shall be applied to all unfinished surfaces of the embedded parts and gates which shall remain exposed to atmosphere or submerged in water to obtain a dory film thickness of 70 microns, which shall be followed by two / three coats at an interval of 24 hours of solventless coat-tar epoxy paint, so as to get a dry film thickness of 150 / 100 microns in each coat. Total dry film thickness of all the coats including primer coating shall be less than 350 microns. d) All finished surfaces of ferrous metal including bolts, screw threads, etc., that will expose during shipment or while awaiting installation shall be cleaned and given a heavy uniform coating of gasoline soluble rust preventive compound or equivalent. e) AJI exposed surfaces for hoists supporting structures shall be given two coats of zinc phosphate primer to obtain dry film thickness of 40 microns per coat which shall be followed by one coat of alkyed based micaceous iron oxide paint at dty film thickness of 65 microns and then two coats of synthetic enamel paint
Part A 35
to obtain dry film thickness of 25 microns per coat. The total dry film thickness of all the coats including primer coat shall not be less than 175 micron. f) All other surfaces to be painted shall be primed with one coat of an approved synthetic varnish vehicle, rust preventive and lead paint. The surface which will be inaccessible after assembly shall be given an additional coat (total two coats) of the same paint.
2.11.4
Measures During Painting
a) Any bare spots or holidays shall be recoated with additional application of primer. b) All runs, sags, floods, or dips shall be removed by scrapping and cleaning, the cleaned area shall be retouched or all such defects shall be remedied by reblasting or re-priming. c) Special attention shall be given to obtaining good coverage on rivets, welds and sharp edges and corners. d) Suitable measures shall be taken to protect applied primer from contact with rain, fog, mist, dust or other foreign matter until completely hardened and next coat applied. e) The air temperature at the time of application must not be below 10 Deg. C and relative humidity must not be above 60%. 2.11.5 Application Procedure
All paints and coating materials shall be in a through mixed condition at the time of application and shall not be thinned except as hereinafter specifically provided. Any warming of the paint shall be performed by means of hot water bath. On all surfaces, to which paint shall be applied immediately after cleaning, and except otherwise specifically provided, shall be applied by either brushing or by spraying. When paint is applied by spraying, a mechanical agitator type of paint pot shall be used. Means shall be proved for removing all free oil and Posture from the air supply lines of spraying equipment. Each coat of paint shall be free from runs, sags, pin holes and holidays. Each coat of paint shall be allowed to dry or harden thoroughly before the succeeding coat is applied. ll paints shall be applied by skilled workmen in a workmanlike manner. Paint shall not be applied during damp weather and on surfaces that are not entirely free from moisture. Rust preventive compound shall be applied by any convenient method to
Part A 36
ensure complete coverage of heavy coating. After the final application. the paint film shall be allowed to cure at least for 7 days. 2.11.6 Field Painting
The painted metal work shall be handled with care so as to preserve the shop coats. The area of the shop paint which has been damaged during transport shall be cleaned to base metal and repainted. Paint applied to such areas shall be of the same type as used originally in shop painting. All unfinished surfaces of embedded parts and gates that are exposed to atmosphere or submerged in water shall be given a finishing paint of Aluminium-Epoxy paint to as to obtain shining surface of pleasing colour. This finishing coat should be able to reflect light and limit the heat absorption when exposed to sun. 2.12 INSTALLATION, OPERATION & MAINTENANCE MANUALS
For guidance during the installation of the work and subsequently for guidance of the plant operating and maintenance staff, Manufacturer shall prepare requisite manuals. The manuals shall include a separate and complete section describing the normal and emergency operating procedures for the gates and control equipment and shall include easily read diagrammatic drawings of the equipment to facilitate understanding of the descriptive information. The manuals shall describe and illustrate the Procedure for assembling. adjusting, operating and dismantling of each component and control system. The maintenance of each component shall be described, including the recommended frequency of inspection and lubrication. Manuals shall also describe and illustrate procedures for installation, storage, handling, unloading, reloading, unpacking and upkeep of each component and of the system. Three (3) copies of the manuals shall be submitted in English in draft form for approval of Engineer three months prior to the time the information is at site. Six (6) suitably bound copies shall be provided to Engineer not later than days after receipt of approval.
If revision of the manuals becomes necessary, as a result of information gained during installation and initial operation, Manufacturer shall make the necessary revisions and furnish six (6) copies of the revised sections. The manuals shall include a complete list of all drawings prepared by Manufacturer, a list of spare parts and a list of parts for each component or item of equipment.
Part A 37
The parts list shall include manufacturer's name and serial numbers and source of their procurement. Manufacturer shall ensure that his Erection, Installation Supervisor has a copy of all approved drawings and the manuals in his site office. 2.13 ERECTION TOLERANCES
The Erection Tolerances shall be as per relevant Indian Standards or their corresponding International Standards. However the following is given as a general guidance. 2.13.1 Gates (Diversion Weir Undersluice, Intake & Desilting)
A. 1.0 1.1 1.2 1.3 2. 2.1 2.2 3. 3.1 3.2 3.3
Embedded Parts
Tolerance limit in mm
Track Plates Alignment in plane parallel to flow Distance between centre line of opening and track Coplanerness Guides Alignment in plane parallel to flow Distance between centre line of opening and face of guide Side Seal Seats
1.0 1.5 1.0
1.0 1.0
Alignment in plane parallel to flow 2.0 Distance between centre line of opening and side seal seat 1.5 Coplanerness 1.0
4.
Top Seal Seat
4.1 4.2 4.3 5. 5.1 5.2

Part A
Alignment Height above sill Coplanemess with side seal seat Critical Dimensions Centre to centre distance between track plates Centre to centre &stance between side seal seats
38
2.0 3.0 1.5
3.0 3.0
5.3 5.4 5.5 B. 1 1.1 2 2.1 2.2 3. 3.1 3.2 3.3 3.4
Face to face &stance between guides Face of track to face of side seal seat Face of track to centre fine of guide Gate Wheels Alignment of treads in zero eccentricity position Side and Top Seal Base Alignment Coplanerness Critical Dimensions
2.0 0.0 2.5
1. 5
1.0 1.0
Centre to centre distance between seal bases 2.0 Centre to centre distance between centre line of wheel treads 2.0 Face to face distance between faces of guide shoes or guide rollers 3.0 Face to face distance between wheel tread to side seal base +2.0 -0.0 3.5 Distance between faces of wheel tread& centre line of guide shoe/roller 2.5 2.13.2 (A) 1 1.1 1.2 1.3 STOPLOG (Diversion Wier Undersluice, Intake & Draft-tube) Embedded parts Side Seal Seat Alignment in plane parallel to flow Distance between centre line of opening and seal seat Coplanerness
0.5 1.5 1.5
2. Side Guide Track 2.1 2.2 2.3 3. 3.1 Alignment in plane normal to flow Distance between centre line of opening and guide track Alignment in plane parallel to flow Bottom Seal Seat Alignment in horizontal plane 0.25 1.00 1.00 1.00
Part A
39
Khiraoganga Small Hydro Electric Project Tender Documents Specifications: Volume II B Hydro Mechanical Part B
PART B - PENSTOCKS
PART B - PENSTOCKS ............................................................................................................................... I B. PENSTOCKS ....................................................................................................................................... 1 1.1 1.2 1.3 1.3.1 1.3.2 1.3.3 1.3.4 1.3.5 1.3.6 1.3.7 1.4 1.4.1 1.4.2 1.4.3 1.4.4 1.4.5 1.4.6 1.4.7 1.4.8 1.4.9 1.4.10 1.4.11 1.5 1.5.1 1.5.2 1.5.3 1.5.4 1.5.5 INTRODUCTION ................................................................................................................................. 1 SCOPE OF WORK ............................................................................................................................... 1 DESIGN DATA ................................................................................................................................... 1 GENERAL REQUIREMENTS............................................................................................................ 2 LAYOUT ....................................................................................................................................... 2 SPECIFICATIONS & STANDARDS ................................................................................................... 3 DESIGN CRITERIA......................................................................................................................... 3 MATERIALS .................................................................................................................................. 3 LOADS TO BE CONSIDERED .......................................................................................................... 4 PENSTOCK VALVE ........................................................................................................................ 5 CONSTRUCTION FEATURES ............................................................................................................... 6 FABRICATION OF STEEL LINER ..................................................................................................... 6 PREPARATION OF PIPE SECTIONS ................................................................................................. 6 CUTTING THE PLATES .................................................................................................................. 6 PREPARATION OF PLATE EDGES AND OPENINGS .......................................................................... 6 STIFFENER RINGS ......................................................................................................................... 7 BENDS .......................................................................................................................................... 7 UNIT AND MATCH MARKING ....................................................................................................... 7 PREHEATING AND THERMAL STRESS RELIEVING ......................................................................... 8 BUTT STRAPS ............................................................................................................................... 9 ALIGNMENT AND TOLERANCES ............................................................................................... 9 NON DESTRUCTIVE EXAMINATION ........................................................................................ 10
ERECTION ....................................................................................................................................... 11 INSPECTION DURING FABRICATION AND ERECTION ................................................................... 12 TESTING AT CONTRACTORS PREMISES ...................................................................................... 12 TESTING AT SITE ........................................................................................................................ 13 CORROSION PROTECTION ........................................................................................................... 13 SUBMITTALS .............................................................................................................................. 13
Tender Documents Specifications: Volume II B Hydro Mechanical Part B
B. PENSTOCKS 1.1 Introduction i) A single penstock of 1.60 metre dia takes off from the bottom of surge shaft with its centre line at EL 2442.60 metre. The entire length of 140.00 m (approx.) has been proposed to be laid on surface. Penstock bifurcates into two branch penstocks of 1.15 metre dia each. The bifurcation length 2 x 15= 30.00 metre (approx.) ii) Economical diameter of the main penstock and two branches have been worked out by cost optimization studies. The main penstock is 1.60 m dia circular steel designed to carry 7.0 cumecs of discharge at a flow velocity of 3.48 m/s, while two branches are 1.15 m dia circular steel and each has been designed to carry 3.5 cumecs of discharge at a velocity of 3.37 m/s. The specifications take into consideration that the maximum width of steel-plates in India is limited to 2.50 m. The Contractor has to decide whether the pipe sections will be fabricated in his workshop and transported to the site or he will build a field work shop to produce the 1.60 m and 1.15 m diameter pipes at Site in order to prevent the damage or de-shaping of pipes during transportation The total length of the branches and penstock given above may vary subject to adjustment to suit the final dimensions adopted for the detailed layout.
iii) iv)
v)
1.2
Scope of Work The work comprises of the design, fabrication, shop assembly, testing, stress relieving, Shop painting, transportation, supply, erection, field painting, testing and commissioning of the penstock comprising of straight shells, bends, bifurcation, reducer, make up pieces, connection piece between penstock branches and flanged connection of main inlet valve etc. & piezometric connection complete in all respects in accordance with these specifications, specification drawings. The scope of work also covers supervision of unloading, stacking, storage and preservation of components of penstock and its accessories, in the stock yard of the contractor at the project site before the same are transported, installed, tested and commissioned at their respective sites. In addition to above, scope of work also includes spares parts required for satisfactory operation and maintenance of penstock liners and its accessories for a period of 5 years from the date of commissioning of the project. Not withstanding brief description of items, all accessories, apparatus or works not sufficiently mentioned in these specifications but which may other wise be necessary for ensuring complete supply, erection, testing and commissioning of the equipment covered under these specifications shall be deemed to be the responsibility of the contractor. Design Data The design data for the penstock and steel lining is broadly appended below: a) Full reservoir Level (FRL) b) Max Water Level (MWL) c) Surge level 2450.0 m 2449.20 m 2453.0 m
1
1.3
Part B
d) Axis of Butterfly valves e) Axis of Inlet Value (f) Max. Tail water level (g) Rated flow
2442.60 m. 2381.01 m 2382.60 m 7.00 cumecs
h) Max. pressure due to water hammer and 85m (Tentatively based on 30% pressure rise) water column (WC), related to the access of the turbine C.L. intake elevation of 2382.00m. i) 1.3.1 i) Headloss in the Penstock at design discharge of 7.2m3/s shall not exceed 2.0m
General Requirements Plates of normalized fine grain steel conforming to IS:2002 Grade 2 or approved equivalent shall be used and shall be 100% ultrasonically tested and certified at the Manufacturers shop. The penstock and steel liner, bends and branch pipes bifurcation etc shall be subjected to hydrostatic testing. The welded joints shall be subjected to appropriate NDT as specified. It is intended that all shop fastenings and field fastenings shall to be of welded type unless otherwise specified. Wherever possible, fabrication at site should be done by automatic welding. Suitable equipment for doing such type of work is a pre-requisite for a tender being considered. The manufacturer must have in his shop, satisfactory facility of plate bending, edge preparation and end milling of members as advised by Engineer-in-Charge. Fabrication of steel work shall be at the manufacturers regular workshop or at a field workshop to be set up by the Contractor in the project area. Shop fabrication of heavy parts and other specials, requiring precessions finishing such as bends, bifurcation and branch pipes shall be done in regular workshops. The Contractor shall arrange at his own cost the transport of such materials to the site as well as fabricated materials from his regular workshop to the project site and finally to the erection site. Any loss or damage in transit on account of this shall be to the Contractors account.
ii)
iii)
1.3.2 i)
Layout The Contractor shall prepare complete all preliminary works at site well before the arrival of penstock and steel liner such as keeping in readiness of electrical winches, rail tracks, mobile cranes, all poles, all tools and tackles, welding sets etc. as part of this contract, together with any other work that may be necessary to start erection immediately. The Contractor shall arrange for such number of erection equipment, supervision, labour and other arrangements as are necessary to carry out the work efficiently and in accordance with an approved programme of work. The Contractor shall be solely responsible for correctness of laying the penstock and steel liners. The checking and approval by the Engineer-in-Charge will not absolve the Contractor from the responsibility of erecting the penstock and steel liner in true alignment. Establishing and maintaining temporary benchmarks and connecting to the permanent benchmarks by double leveling shall be the responsibility of the Contractor for which no extra payment shall be made.
ii)
Part B
1.3.3
Specifications & Standards These specifications are intended for the partial description of quality, workmanship etc. desired for the items covered in the General Technical Specification and scope of work. Specifications are not however, intended to cover all the minute details and the work shall be executed in accordance with the spirit of the tender specifications. In the absence of specifications for any particular item of work it shall be executed as per relevant IS Code (latest revisions) IS: 2825 i.e. Indian Standard Code for Unfired Pressure vessels. In case neither of the above mentioned specification and code are available for any particular item of work, the work shall be executed as per section VIII ASME Unfired pressure Vessel code and ASTM Standard or as directed by the Engineer-in-Charge. These specifications shall be read in conjunction with the description of the items in the schedule of items. Design Criteria The Penstock and steel lining shall be designed with the following objectives: a) Internal water pressure corresponding to the Max, Water Level (MWL) of 2453.00 m is 71 m, b) Internal dynamic water pressure including water hammer, 85.00- m water head, c) External static water pressure of 5.00 m while the steel liner is empty.
1.3.4
1.3.5 Materials i) All materials incorporated in the Works shall be of first-class quality, free from defects and imperfections and, where shown, of the classifications and grades designated. Materials not specifically designated here in shall be suitable for the purpose intended and shall, as far as practicable, comply with the latest specifications of the American Society of Testing Materials (ASTM) and the ASME Boiler and Pressure Vessel Code Section VIII, division 2 or equivalent European Standard. ii) Plate material for penstock and steel liners shall be IS:2002 Grade 2 or approved equal. All steel shall be fine grained, fully killed, not subject to brittle fracture, non-ageing, and highly weldable with yield strength of 255 Mpa. iii) Material certification and testing shall be per ASTM A 20 (suitable for IS:2002 Grade 2) and ASME Boiler and Pressure Vessel Code Section VIII, Division 2 and with supplementary requirements as in the following paragraphs of ASTM A20: a) b) c) S5: Charpy-V-Notch toughness tests at-20 C in transverse direction of each plate. S4: On total 3 plates of y = 255 Mpa steel material. One bend test as follows: One on plate with most frequently used wall thickness, One on plate with maximum wall thickness, One on plate with an intermediate wall thickness. d) iv) S8: Ultrasonic examination.
Complete mill test reports are to be submitted with above certification showing results of all
3
Part B
mandatory and supplementary requirements: a) b) c) d) Steel Tubes Certification; The Contractor shall provide a certificate for each steel pipe section and bifurcation as stipulated in this Chapter. Steel material of the same quality (IS:2002 Grade 2) or approved equivalent shall be used. All materials used, fabricated and welded to the liners and penstocks which are not particularly specified above shall be compatible in respect to chemical, mechanical and welding properties as defined by ASME Code. Welding consumables shall be as per AWS Filler Metal specifications as recommended by the steel manufacturer. Only suitable Low hydrogen welding consumables shall be used for welding. Consumables shall be baked as recommended by the consumable manufacturer to moisture levels required by the steel manufacturer. FCAW electrodes and SAW flux electrode combinations shall be certified by the manufacturer to meet the diffusible hydrogen limits given below. Diffusible hydrogen shall be determined in accordance with AWS A 4.386. Specified weld Metal strength 485 Mpa (70,000 psi) 760 Mpa (110,000 psi) e) Max. Hydrogen (ml/100 g) 15 5
Temporary and embedded supports for securing liners and penstocks during concreting shall be of good quality and suitable for the intended purpose. In addition, the same precautions shall be exercised when any attachment is welded to the steel liners. Loads to be Considered The following loading conditions shall be considered in the design of penstock and steel lining: Normal Operating Condition: - Internal water pressure corresponding to maximum water level in the reservoir along with pressure rise, due to normal operation or head at transient maximum surge, whichever is higher. - External water pressure on steel liner corresponding to 5.00 m terrain height. - Internal Water Pressure due to water hammer.
1.3.6 i) a)
b) c) d) e) f) ii)
Intermittent condition includes those during filling and draining of penstocks and maximum surge in combination with pressure rise during normal operation. Emergency condition includes partial gate closure in critical time of penstock (2L/a second) at maximum rate, and the cushioning stroke being inoperative in one unit. Exceptional condition includes slam shut, malfunctioning of control equipment in the most adverse manner resulting in odd situation of extreme loading. This should not be taken as design criteria. The steel lining shall also be designed for the external water pressure head corresponding to 5.00m terrain height. . The penstock steel liners and their anchor rings shall be designed to transfer the complete axial thrust under transient condition to the powerhouse upstream rock-mass. No load shall be transferred to the inlet valve foundation. The penstock rests on support and acts therefore as a longitudinal beam It must be designed for internal pressure and as well as external load due to 50% vacuum in the empty tubes. Poisson effect must be considered if unfavorable. a) The following loads shall be taken in to consideration: - Weight of the tube
4
Part B
b)
- Weight of the water filling, - Internal dynamic pressure, - Stresses due to supporting and stiffening rings, - Stresses in bends and anchor points, - stresses due to temperature variation, - Seismic effects. Stress calculations:
The resultant stresses shall be calculated according to the theory of V. Mises, Hencky and Huber. iii) The following safety factors shall be applied in relation to the yield strength of the steel: Description Penstock & Steel Liner Bifurcation (Manifold) (including Branch Pipes) Safety factor for internal pressure excluding normal water hammer effect Safety factor for internal pressure excluding normal water hammer effect Safety factor against buckling with external water or grouting pressure on an empty lining (for embedded steel lining) Safety factor against buckling with 50% internal under-pressure an external atmospheric condition 1.8 2.0
1.5
1.8
1.5
1.8
1.2
iv)
The allowable stresses in design of steel penstocks shall be as per IS: 11639 (part-1). Penstock Valve
1.3.7
A manually/motor operated penstock valve 1600 mm dia. of butterfly type with geared drive will be provided in the valve house to facilitate maintenance of inlet valves in power house. The opening of the valve shall be through motor /manual handle in conjunction with geared drive and closing of the valve shall be through counterweight initiated by closing signal from over velocity device/ manual push button. The valve shall also be provided with means for remote closing from power house. The penstock valve shall be suitable for an operating head of 20m. The valve shall be suitable for opening/closing under unbalanced conditions. The valve shall be provided with service and maintenance seals. The valve body shall be welded construction, with its operating feet to take all vertical loads at foundations. The body shall house door trunions complete with self lubricated PTFE bushes for bearings. The valve shall be provided with air release / vacuum valve to maintain the atmospheric pressure inside penstock during filling or emptying operation of the penstock. A 150 mm dia penstock dewatering pipe
Part B 5
with a valve shall be provided to empty the penstock upstream of the penstock valve. The valve shall be provided with flanges on upstream and downstream sides for connection to penstock. The downstream flange shall be provided with spacer flange to facilitate dismantling of the penstock valve. A chain pulley block of adequate capacity shall be supplied along with valve for erection and maintenance of the same. 1.4 Construction Features
1.4.1 Fabrication of Steel Liner The fabrication of the penstock pipes, the steel liners, the bifurcation and the turbine branch pipes shall be in accordance with the specifications, drawing and the corresponding approved design and fabrication drawings and Indian Standard for unfired pressure vessels (IS: 2825) or the equivalent standard specified under this Chapter. In case of any difference between the above this particular Technical Specification shall govern. 1.4.2 Preparation of Pipe Sections i) Each section of pipe shall be made with the minimum number of plates depending upon the availability of plate sizes or as directed by the Engineer-in-Charge. ii) In the case that three plates are used the longitudinal welds shall be staggered at approximately 120 about the centre line of the pipe. When two plates of almost equal lengths are made available, the longitudinal joints shall be located at quarter points and staggered between sections. When two plates of equal lengths are not made available or when the section is made of a single plate, the longitudinal joints/joint shall be placed approximately at 90 from the vertical centerline of the pipe and shall be staggered in adjoining sections. The longitudinal welds shall be located so that they do not intersect the nozzles, manholes, or other outlets. The normal lengths of each section shall be limited to plate width available. When three plates are used, the displacement angle of the joint from the vertical centerline may be approximately 45.
1.4.3 Cutting the Plates Plates to be welded shall be cut to size and shaped by machining and/or flame cutting, where the plate thickness does not exceed 25 mm, cold shearing may be used provided that the sheared edge is cut back by machining or chipping for a distance one quarter of the plate thickness but in no case less than 3 mm. 1.4.4 i) a) b) Preparation of Plate Edges and Openings Weld preparation and openings of the required shapes may be formed by the following methods: Machining/chipping or grinding: Chipped surfaces which are not covered with weld material shall be ground smooth after chipping, Plate cutting, which includes plasma arc, oxy-acetylene gas with or without flux injection or equivalent fusion cutting process. Any material damaged in the process of cutting plates of size shall be removed by machining, grinding or chipping back to sound metal. Surfaces which have been flame cut shall be cut back by machine grinding so as to remove all burnt metal, notches, slag and scale but slight discoloration of machine flame cut edges on mild steel shall not be regarded as detrimental.
6
Part B
ii)
After the edges of the plates have been prepared for welding they shall be given a through visual examination for flaws, cracks, laminations, slag inclusion or other defects. When plates are flame cut, the edges should be examined after this operation. Edges which have been flame cut shall be cut back by machining or chipping for a distance of one quarter of plate thickness but in no case less than 3 mm. Rust, Scale, painting, oil, slag etc. from the flame cutting or other contamination of the fusion pieces shall be removed before welding is commenced. The surfaces to be welded shall be free from foreign materiel such as grease, oil or marking paint for a distance of at least 25 mm from the welding edges. Irregularities in fusion face, which are likely to affect the quality of welding, shall be removed before welding is commenced. All plates edges after cutting and before carrying out further work upon them shall be examined for lamination and also to make certain that marks have not been caused by shearing. Plates for shell sections shall be formed to required shape by a process that does not impair the quality of the material. However, correction of curvature by blows will not be permitted. Cold-formed plate material shall not be subjected to a deformation of more than five percent, unless suitable heat treatment is carried out after such forming. Heat treatment shall, however, be carried out even when the deformation is less than 5 percent if there is pronounced risk of brittleness through ageing. The deformation expressed as a percentage is obtained from the formulae: Deformation = (t x 100)/D, t = thickness of plate, D = internal diameter to which the plate is being bent or formed.
iii)
iv)
Cold forming shall not be undertaken when the temperature of the metal is less than 0C. If the forming or bending takes place in hot condition and if the final shape in process terminates within the correct temperature limits for the particular material, no subsequent heat treatment is required. Where two plates at a welded joint differ in thickness the thicker places shall be trimmed to a smooth taper as per Para 6.3.5 IS 2825-1969.
v)
1.4.5 Stiffener Rings Stiffener rings shall be fabricated in not more than eight circumferential sections butt welded together and properly fitted and welded to the pipes, so that the plane of rings will be normal to the axis of the pipe. The height of the rings shall be less than 175 mm. 1.4.6 i) Bends Bends shall be made of short segment of pipe with mitered ends. The segments shall be made with equal deflection angles except for the end ones, which shall be of smaller deflection angles than the other segments. The number of segments along with stiffener rings shall be adequate to take care of the loads. The plates of miter bends shall be arranged such that in the centre line the angel deflection between two adjoining plates does not exceed 7.
ii)
1.4.7 Unit and Match Marking i) Each part of the penstock and steel liner section, curvature of the shell or surface to which they
Part B 7
are attached or its auxiliary parts shall be legibly marked to show the unit of which it is a part and match marked to show its relative position w.r.t the finished structure to facilities assembly in the field. To ensure proper matching of sections at the joints, expanding struts, spiders may be used. Each section shall be marked to show top of vertical diameter and the direction of the flow. Unit marks and match marks shall be made with heavy stamps and with paints. The contractor shall prepare marking drawings of each penstock and steel liner section, indicating clearly the location of each section an appurtenant parts w.r.t. the completed structure and shall furnish such drawings. ii) If penstock and steel liner sections are transported for a long distance temporary bracings/spiders shall be provided to prevent deformation.
1.4.8 i)
Preheating and Thermal Stress Relieving When preheating is the part of the approved welding procedure, weld joints shall be preheated in accordance with the kind of steel materials and plate thickness. Maximum inter-pass temperature of preheating shall be 200C and preheating area shall be over a distance of more than four times of plate thickness for each side from the welding joints. If welding work is made under the condition of ambient temperature less than 5C, steel materials on weld joints shall also be preheated even though application of preheating is not required due to the kind and thickness of the steel materials under normal welding conditions. The relation between the carbon equivalent and the preheating temperature in cases of manual welding, shall be as follow: Carbon equivalent (Ceq) [%] 0.00-0.28 0.28-0.38 0.28-0.38 0.38-0.48 0.38-0.48 More than 0.48 Plate thickness [mm] 0-100 0-25 25-100 0-25 25-100 0-100 Preheating temperature for low hydrogen welding rods [C] 40-60 40-60 80-100 100-150
ii)
iii)
Note: Ceq (%) = C+1/6 Mn + 1/24 Ni + 1/5 Cr + Mo + 1/14 and Cu, P, etc., could be added as necessary. iv) Post weld thermal stress relieving shall be a part of approved welding procedure and shall be carried out in accordance with the relevant provisions of ASME boiler and pressure vessel code Section VIII Division-2 or IS:2825. The method statement and procedure for conducting thermal stress relieving shall depend upon the particular structure, grade and composition of steel and thickness involved. The contractor shall obtain prior approval regarding the above from the Engineer-in-Charge.
Part B
1.4.9 Butt Straps Butt straps on the outside of sections, are foreseen to be used on the penstock and steel lining to facilitate making the circumferential joints in-situ. Each complete butt strap should be arranged in two halves, the bottom half being welded in the shop to the erection section to be erected first, the other half of the butt strap being also welded in the shop to the following erection section. This arrangement facilitates placing the adjoining erection sections at the site. When adjoining sections are in their final positions the butt straps should fit closely to the adjoining shell thereby enabling satisfactory welded joint to be obtained. All in-situ welding of the penstock and steel lining must be carried out from the inside. After finishing the welding work inside the pipe the outside connection between pipe and butt ring must be closed by a sealing weld on both sides of the butt strap. 1.4.10 Alignment and Tolerances General: The sections of the completed penstock and steel liners shall be circular within the limits defined here under. Measurement shall be made to the surface of the parent metal and not to a weld, fitting or other raised part. There shall be no flats or peaks at welded seams and the local departure from circularity shall be gradual. Alignment : Before any welding is commenced, it shall be ascertained that the chamfered edges are in alignment and that the defects in alignment at the surfaces of the plates are less than: For plates of thickness 5 mm or less t/6 for a longitudinal seam and t/4 for circumferential seam subject to a maximum of 1 mm, For plates over 5 mm in thickness Before any welding is commenced it shall be ascertained that the prepared edges are in alignment to meet the requirement of the welding process and that the defects in alignment at the surface of the plates are not more than: 10 percent of the nominal plate thickness with a maximum of 3 mm for longitudinal joint. However, for plates up to and including 10 mm thick a misalignment of 1 mm is permitted, 10 percent of the maximum nominal plate thickness plus 1 mm with a maximum of 4 mm for circumferential joints. Circumference: The circumference shall conform to Para 6.6.3 of IS: 2825-1969. Out of roundness of sections: The difference between the maximum and minimum diameters at any cross section of a section welded longitudinally shall not exceed 1 % of the nominal internal diameter subject to a maximum of (D1 + 1250)/200 where D1 is internal diameter in mm. The individual cylindrical section shall be reasonably square and straight. The plane of the pipe section ends shall be normal to the axis of the pipe within a tolerance of 2 mm on the radius. The edges of the plates of each section shall be properly prepared of field welding. Unless otherwise specified the out of straightness of the section shall not exceed 0.3% both of the total cylindrical length or any 5 m length (This tolerance may be omitted where the individual section length does not exceed 2m). Attachments and fittings: All lugs, brackets, saddle type nozzle, reinforcement around openings and other attachments shall conform reasonably to the curvature of the section or surface to which they are attached.
Part B 9
1.4.11 Non Destructive Examination Radiographic examination: All longitudinal joints and shop circumferential joints of penstock and steel liner including bends, shall be subjected to 100% radiographic examination. 10% length of each of the field circumferential joints along with all T-joints shall also be tested radiographically. The procedure of the radiographic examination, the acceptable standards of welds, the repair of defective welds and the re-examination of repaired welds shall conform to the relevant section of IS: 2825, IS: 2595, IS: 1182 and IS: 4853. All repairs shall be fully radiographed. If the examination shows major defects the qualification of the welder must be tested and the radiographic examination will be extended according to the instruction of the Engineer-in-charge at the costs of the contractor. Ultrasonic examination: The remaining all length of all circumferential field welds, which were not spot radiographed or such joints, which in the opinion of engineer-in-charge are difficult to be radiographed, or inaccessible to radiographic examination shall be subjected to 100% ultrasonic examination. The procedure for the ultrasonic examination, the acceptance standards for welds etc. shall conform to the relevant articles of ASME Boiler and pressure vessel code-Section-V. Other Examination: Discontinuities such as cracks, seams, laps, cold shuts, laminations and porosity can be detected using other methods viz: Dye Penetrate Examination, (DPE) Magnetic Particle Examination, (MPE) All weld metal build up shall be examined over the full surface of the deposit either by liquid penetrant examination or by magnetic particle examination. All permanent hold down logs or devices welded to the steel penstock shall be examined by either of the above two methods. Removal of temporary lugs and devices tack welded to the penstock and steel liner section and subsequent dressing shall be follows by either of the above two examinations viz. DPE or MPE of the connection area .The procedure and acceptance standards for the above methods shall conform to the relevant articles of ASME boiler and pressure vessel code-Section-V. The notch toughness of welds and heat-affected zones shall be determined using charpy-V notch impact tests. Impact tests shall be in accordance with the requirement of relevant article of ASME Code3, Sec. VIII, and Div. 2 and made on procedure qualification test plates and vessel test plates of the material to be fabricated. The cost of welds tests such as radiographic, ultrasonic, magnetic particle/dye penetrant examination shall be borne by the Contractor and shall be included in the rates. Prior to making the radiographs of the welds such markings shall be so designed and located that the images will appear in the radiographs. The markers shall be painted, stamped or fastened to the shells as directed by the Engineer-in-Charge and shall not be removed until all the welds have been accepted. All X-ray films of the joints shall be the property of the Purchaser and shall be
Part B 10
forwarded properly identified to the Engineer-in-Charge for record. Radiography by X-ray may be replaced by Gamma ray methods using Cobalt-60, Iridium-192, Ceasium-187. Records of all non destructive tests including radiography, ultrasonic test, dyepenetrant test, magnetic particle inspection shall be maintained in a suitable format to be evolved in consultation with the Engineer-in-Charge showing the unique identification of the weld, its location, size, extent of flow, if any and interpretation of the results of the nondestructive test along with the results of repairs, if any. 1.5 i) Erection Before erection is started the Contractor shall supply eight complete sets of erection schedules, procedures and erection drawings to the Engineer-in-Charge for approval. The Contractor will be required to erect the penstock and steel liners in place and do the welding of field joints. All civil works e.g. excavation, concreting and back-fill as also of the anchor and foundation for supports etc. will be done by others. Erection Procedure: a) The steel liners shall be assembled in the field in accordance with erection drawings. The liners sections shall be installed in place accurately, to line and grade/plumb and held securily by means of steel straps over the temporary erection supports and supporting brackets and embedded in concrete. When assembled and ready for welding, the distance between the ends of adjoining sections which are to be connected together with the field circumferential welds shall not be greater than 3 mm as per joint details and shall be of 6 mm in case of joint with backing strips. Care shall be taken to avoid excessive length, growth or shrinkage in pipe lengths, The Contractor shall furnish and install such permanent structures, erection supports permanent or temporary including holding down straps and internal bracings as may be required to support the liners securely in place and prevent distortion during erection, welding and placing of concrete. Cost of all such structures including erection supports (permanent or temporary) shall be included in the unit rate of various items. The circumferential seams shall then be welded as soon as practicable. After field welding by the electric arc method of circumferential seems the joints are to be tested radiographically/ultrasonically/penetrate method or spot radiography as given under non destructive examination, and if any joint is found defective the same shall be repaired to the satisfaction of Engineer-in-Charge To ensure the matching of sections at the joints expanding struts or spiders may be used. Tack welds where used to hold the sections in line, shall be removed so that they may not become part of the joints. A clear space of 0.8 m at the bottom portion of steel lining from bottom bend to bifurcation shall be made enable the welding of circumferential joints and spot radiography etc. at erection site, The schedule of installation of pressure steel liner on the supports and the field welding and embedment in concrete have to be carefully synchronized with the works of the civil contractor who shall be doing the concreting of pressure shaft. When the penstock and steel lining has been installed, with all structural supports, rods, wedges, etc. as may be required to hold the pipes securely in place, all such work shall be inspected and approved by the Engineer-in-Charge for embedding in concrete, It shall be ensured by the Contractor that the provision of supports (permanent or temporary) and chairs are sufficient to prevent any misalignment of the pressure shaft due to buoyancy of wet concrete during concreting,
11
b)
c)
d)
e)
Part B
f)
When erection, welding and inspection of the steel lining have been completed in accordance with these specifications, the steel lining, bifurcation, and branch pipes shall be encased by concrete. The Contractor shall supply and install sufficient interior bracings in addition to that required for welding to maintain the roundness within the specified tolerances until the encasement is completed. The Contractor shall supply and install sufficient exterior bracings and anchor bands and bars to resist the loading due to the placing of concrete from the outside of the steel liner. All the internal bracings and foreign matter shall be removed from the inside of penstock after the penstock has been erected and embedded in concrete.
1.5.1 i)
Inspection During Fabrication and Erection The Engineer-in-Charge or his duly authorized representative shall have at all reasonable times access to the Contractors premises of works and shall have the power at all reasonable time to inspect and examine the materials and workmanship of the penstock and steel liner during its manufacture or erection at Contractors premises or works site respectively. If part of the plant is being manufactured or erected in other premises or works, the Contractor shall obtain for the Engineer-in-Charge and for his duly authorized representative permission to inspect during fabrication and erection of the penstock and steel liner as if the plant of material were manufactured on the Contractors own premises or works. The Engineer-in-Charge shall, on giving seven days notice in writing to the Contractor setting out the grounds of objections which he may have in respect of the work and he would be at liberty to reject all or any materials plants or workmanship which is the subject of any of the said grounds of objection and which in his opinion are not in accordance with the Contract or are in his opinion defective for any reasons whatsoever. The contractor shall withdraw immediately all such defective material/components and replace them completely. If such notice is not sent to the Contractor within reasonable time after the grounds upon which notice is based have come to the knowledge of the Engineer-in-Charge, he shall not be entitled to reject the said materials, plants or workmanship on such grounds, unless specifically provided otherwise. All tests shall be made at the Contractors works before transport. The Contractor shall give the Engineer-in-Charge or his duly authorized representative notice of group of components that are ready for testing and engineer-in-charge shall, on giving twenty four hours previous notice in writing to the Contractor, attend at the Contractors premises of works within twenty one days of the date on which the material is notified as being ready failing which, the Contractor may proceed with the tests, which shall be deemed to have been made in the Engineer-in-Charges presence and he shall forthwith forward to the Engineer-in-Charge duly certified copies of the test certificates induplicate.
ii)
1.5.2 Testing at Contractors Premises i) In all cases, where the Contractor provides for test whether at his premises of work or of any sub contractor, the Contractor except where otherwise specified shall provide free of charges, such labour, material electricity, fuel, water, stores, apparatus and instruments as may reasonably be demanded to carry out efficiently such tests of the plant in accordance with the Contract and shall give facilities to the Engineer-in-Charge or his authorized representative to accomplish such testing. If special tests other than those specified in the Contract are required, they shall be paid for by the employer as Variations. ii) When the tests have been satisfactorily completed at the Contractors/Sub Contractors premises or works, the Engineer-in-Charge shall issue a certificate to that effect and no plant shall be transported before such certificate has been issued. The satisfactory completion of these tests or
12
Part B
the issue of the certificate shall not bind the Engineer-in-Charge to accept the plant so passed for dispatch, should it on further tests be found not to comply with the specifications. iii) Hydrostatic Testing
Each section of the penstock liner (including bends as fabricated for field erection) shall be tested Under hydrostatic pressure equal to 1.5 times design pressure, where the design pressure for the hydrostatic tests, shall be computed from the following formula:P= (1.33Yp x t)/D Where, P= Test pressure in kg/cm2. Yp= Yield point stress of steel used in the particular ferrule under test in kg/cm2. T= Actual minimum wall thickness of pipe in cm in the pipe length tested. D= Internal Diameter of pipe in cm. Each pipe shall be completely filled with water and the pressure shall be slowly and uniformly increased until the required test pressure is reached. The test pressure shall be applied and released three times successively and after each application shall be held steady, for at least 15 minutes or till such time until all welded joints and plate has been examined for defects, leaks etc. Any defects in welds or plates disclosed by the hydrostatic test shall be repaired by the contractor to the satisfaction of the Employer and all repaired sections shall be re-tested hydrostatically. 1.5.3 Testing at Site
Wherever possible all tests shall be carried out before dispatch. Should however, it is necessary for the final tests as to performance and guarantees to be held over until the plant is erected at site they shall be carried out in the presence of Contractors representative within one month of the completion of erection. In all such cases except where otherwise specified, the Contractor shall provide free of charge all the facilities, equipment and material as may be required from time to time and as may reasonably be demanded for efficiently carrying out such tests of the penstock and steel liner, material, or workmanship in accordance with the Contract. Should the results of test not come within the margin specified, then test shall, if required, be repeated within one month from the date of the steel lining being ready for re-test and Contractor shall repay to the Engineer-in-Charge all reasonable expense to which he may be put by such tests. 1.5.4 Corrosion Protection
For corrosion protection and surface treatment of penstock liner refer General Technical Specifications. 1.5.5 i) a)
Part B
Submittals The Contractor shall provide drawings and other technical data to the Engineer-in-Charge for approval, as per the following to the extent applicable: Drawing List: A complete list of all drawings and technical data, by title,
13
b) c)
General Arrangement Drawings: Outline drawings to scale, showing relation of the equipment components, materials, and accessories, Detail Drawings: All penstock and liner thickness shall be clearly defined, including stiffener dimensions, if any, and respective welding details shown. All details of equipment and materials required for fabrication and / or assembly shall be clearly defined. These drawings are to be crossreferenced to all other drawings, A QA/QC plans as per ASME Section VIII, Division 2, or equal, shall be submitted. This plan shall also cover subcontract monitoring. The QA/QC plan shall ensure weld trace ability to the welder both for field and shop weld, The plan shall address frequency and scope of fabrication, shop audits and job site erection audits. Also the plan shall define the procedure to be used to ensure that test coupon welding is representative of the actual procedures being executed, Welding procedure specifications with procedure qualification records shall be submitted. All other documents required by ASME Section-IX shall be made available, For high strength steel with yield strength in excess of ----- MPa such as IS:2002 Gr. 2 material, the steel manufacturers detailed welding and post weld thermal stress relieving recommendations shall be submitted for information and review, Material certification shall be submitted to the Engineer-in-Charge with all test results for approval. This also includes welding consumables and miscellaneous materials, All deviations from the Specifications and/or Drawings shall be clearly noted and submitted to the Engineer-in-Charge for approval, Liner Certificates. The Contractor shall provide a certificate with the following information for each penstock, steel liner and bifurcation section: Identifying number of the plates used for the section, Heat number of the plates, Numbers of the appropriate acceptance certificates for the plates Records and numbers of certificates relating to tests performed on plates and on the completed section, Theoretical weight of the complete section, Documentation for welder tractability, to welds, Measured dimensions including plate thickness, section length, circumference, two perpendicular diameters, one of which is measured through the longitudinal weld, ovality and out of roundness, Radiographs, Results of ultrasonic tests
14
d)
e)
f) g)
h) i) j) ii) a) b) c) d) e) f) g) h) i)
Part B
j) k) l) m) n) iii)
Results of surface examination, (MT or PT), Thermal treatment, Results of water pressure tests. Special remarks, Number and dates of the relevant reports. Each certificate shall show in sketch form the sequence of the welds, the position of the radiographs and repair locations. A sample certificate (with hypothetical entries) shall be submitted to the Engineer-in-Charge for review prior to liner shipments.
Part B
15
Tender Documents Specifications: Volume II B Hydro Mechanical Part C
PART C -TECHNICAL DATA SHEETS
1.0 DATA SHEET FOR DIVERSION WEIR SERVICE GATE / ROPE DRUM HOIST DESCRIPTION UNIT CONTRACTOR DATA
1.
2. 3. 4. 5. 6. 7.
8 9. 10. 11. 12. 13. i. ii. iii. iv. v. vi. viii. 14. i. ii. 15. i. ii. 16.
HOIST Capacity including 20 % Tonne Reserve ( To be supported by design calculation) Hoisting Speed Total lift of gate considered. H P and type of motor for hoist Size, type and make of brake for hoist Size , type and make of standard gear box for hoist No. of rope falls and the size, construction of wire rope , its breaking strength No. of rope drum and no. of layers of rope on drum Size and no. Spur gear reduction provided. Size, type and make of flexible couplings provided. Type of position indicator provided. Facility for manual operation of the hoist. Material specification for Rope drum Spur gears Pinions. Shafts Wire rope sockets Bush bearings. Make of plummer blocks. Weight of Rope Drum Hoist & Structure Hoisting Equipment Supporting Structure Type of control Pendent Cabin Operated Corrosion protection system/ Painting schedule
1
Part C
1.1 DATA SHEET OF ROPE DRUM HOIST FOR DIVERSION WEIR SERVICE GATE DESCRIPTION UNIT CONTRACTOR DATA
1.
2. 3. 4. 5. 6. 7.
8 9. 10. 11. 12. 13. i. ii. iii. iv. v. vi. viii. 14. i. ii. 15. i. 16.
HOIST Capacity including 20 % Tonne Reserve ( To be supported by design Capacity calculation) Hoisting Speed Total lift of gate considered. H P and type of motor for hoist Size, type and make of brake for hoist Size , type and make of standard gear box for hoist No. of rope falls and the size, construction of wire rope , its breaking strength No. of rope drum and no. of layers of rope on drum Size and no. Spur gear reduction provided. Size, type and make of flexible couplings provided. Type of position indicator provided. Facility for manual operation of the hoist. Material specification for Rope drum Spur gears Pinions. Shafts Wire rope sockets Bush bearings. Make of plummer blocks. Weight of Rope Drum Hoist & Structure Hoisting Equipment Supporting Structure Type of control Cabin Operated Corrosion protection system/ Painting schedule
Note similar Data sheet shall be submitted for Intake Gate and Desilting Inlet Gate
Part C
2.0 S.NO
DATA SHEET FOR DIVERSION WEIR STOPLOG DESCRIPTION UNIT CONTRACTOR DATA
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
Clear Width of Opening Top of the Gate Sill Level Height of each Stoplog Unit Number of Units Provided Location of Skinplate U/S or D/S Location of Seals U/S or D/S C/c of Tracks C/c of Side Seals Type of Stoplog (Fixed Wheel Type or Sliding Type) No. of Horizontal Girders in Each Unit Are the units interchangeable Type of Side Seals Type of top seal Type of Bottom Seal Weight of Each Stoplog Unit Weight of Embedded Parts Ist stage 2nd stage Operation under balanced/ unbalanced Head Top of track plate Corrosion protection system/Painting schedule Tonne Tonne
18. 19. 20.
Note: Similar data sheet for Intake stoplogs shall be submitted separately.
Part C
2.1 DATA SHEET OF MONO-RAIL CRANE FOR DIVERSION WEIR STOPLOGS DESCRIPTION UNIT CONTRACTOR DATA
1.
2. 3. 4. 5. 6. 7.
8 13. i. ii. iii. iv. v. vi. 14. i. ii. i.
15. 16.
HOIST Capacity including 20 % Tonne Reserve ( To be supported by design Capacity calculation) Hoisting Speed Total lift of gate considered. H P and type of motor for hoist Size, type and make of brake for hoist Size , type and make of standard gear box for hoist No. of rope falls and the size, construction of wire rope , its breaking strength No. of rope drum and no. of layers of rope on drum Material specification for Rope drum Gears pinions. Shafts Wire rope sockets Bush bearings. Weight of Rope Drum Hoist & Structure Hoisting Equipment Supporting Structure Type of control Pendent Corrosion protection system/ Painting schedule
Note: Similar data sheet for Intake stoplogs and Draft Tube gate shall be submitted separately. .
Part C
3.0 DATA SHEET FOR INTAKE SERVICE GATE S.NO DESCRIPTION UNIT CONTRACTOR DATA
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Clear Width of Opening Clear Height of Opening Design Head Number of Openings Number of Elements Provided Number of elements in each gate and how they are assembled at site Type and No. of Bearing in the Wheels Location of Skin plate U/S or D/S Location of Seals U/S or D/S C/c of Tracks C/c of Side Seals Type of Side Seal Type of Bottom Seal Type of Top Seal Weight of One assembled Gate Weight of Embedded Parts 1st stage 2nd stage Type of Hoist and capacity ( To be supported by design calculations) Material Specifications Skin Plate Wheel Wheel Pin Bearing Make & No. Roller Track Seal Seats Gate Operating System Opening Speed Closing Speed Operation procedure Forces considered for hoist capacity Down pull considered during lifting for calculation of hoist capacity Uplift force considered while
5
M M M Nos. Nos. Nos.
M M
Tonne
17
18 i. ii. iii. iv. v. vi. 19. i. ii. iii. 20. i. ii.

Part C
M/min M/min
Tonne Tonne
21 22 23 i. ii. iii. iv. v. vi. vii 24. i. ii. iii. 25. i.
ii.
26.
lowering the Gate for calculation of hoist capacity Complete opening time Complete closing time Material Specifications, thickness, dia, size etc. etc. Skin Plate Wheel Wheel Pin Bearing Make & No. Roller Track Seal Seats Guide Rollers Gate Operating System Opening Speed Closing Speed Operation under balance/ Unbalanced head Forces considered for hoist capacity Down pull considered during lifting of gate for calculation of hoist capacity Uplift force considered while lowering the Gate for calculation of hoist capacity Corrosion protection system/ Painting schedule
Second Second
M/min M/min
Tonne
Tonne
Part C
4.0 DATA SHEET FOR TRASHRACK FOR INTAKE SR. NO. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. DESCRIPTION Maximum differential head considered for the design of vertical bars Maximum differential head considered for other structural members Size of vertical bars and their upstream Profile Size of Horizontal & vertical beams Size of each panel and the total height of trash racks provided. Inclination of the trash rack to the vertical. Clear space between the vertical bars. Weight of each panel and the total weight of trash rack Weight of embedded parts. Material specification of various components. No. of trashracks Sill level Operating deck level Maintenance procedure Corrosion protection system/ Painting schedule CONTRACTOR DATA
Note: Similar data sheet for Trashrack for HRT shall be submitted separately. .
Part C

Tech. Specifications (Civil &amp; HM)

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Mountain Energy Corporation

VOL. 2 DESIGN MEMORANDUM & TECHNICAL SPECIFICATIONS

Khiraoganga Small Hydro Electric Project

Tender Documents Specifications: Volume II A Civil

KHIRAOGANGA HYDRO ELECTRIC PROJECT

Volume II A DESIGN MEMORANDUM AND TECHNICAL SPECIFICATION FOR CIVIL WORKS

Khiraoganga Small Hydro Electric Project

Tender Documents Specifications: Volume II A Civil

Khiraoganga Small Hydro Electric Project

Tender Documents Specifications: Volume II A Civil

Khiraoganga Small Hydro Electric Project

Tender Documents Specifications: Volume II A Civil

Khiraoganga Small Hydro Electric Project

Tender Documents Specifications: Volume II A Civil

Appendix A: Primary Survey Stations ...................................................................64 Appendix B: Table of Tolerances .............................................................................65

Khiraoganga Small Hydro Electric Project

Tender Documents Specifications: Volume II A Civil

PART 1: GENERAL AND PRELIMINARY

Khiraoganga Small Hydro Electric Project

Tender Documents Specifications: Volume II A Civil

Khiraoganga Small Hydro Electric Project

Tender Documents Specifications: Volume II A Civil

Khiraoganga Small Hydro Electric Project

Tender Documents Specifications: Volume II A Civil

Khiraoganga Small Hydro Electric Project

Tender Documents Specifications: Volume II A Civil

Khiraoganga Small Hydro Electric Project

Tender Documents Specifications: Volume II A Civil

Khiraoganga Small Hydro Electric Project

Tender Documents Specifications: Volume II A Civil

Khiraoganga Small Hydro Electric Project

Tender Documents Specifications: Volume II A Civil

Khiraoganga Small Hydro Electric Project

Tender Documents Specifications: Volume II A Civil

PART 2: WORKMANSHIP AND MATERIALS

Khiraoganga Small Hydro Electric Project

Tender Documents Specifications: Volume II A Civil

Khiraoganga Small Hydro Electric Project

Tender Documents Specifications: Volume II A Civil

PART 3: EXCAVATION AND EARTHWORKS

Khiraoganga Small Hydro Electric Project

Tender Documents Specifications: Volume II A Civil

Khiraoganga Small Hydro Electric Project

Tender Documents Specifications: Volume II A Civil

Excavations for Structures

Khiraoganga Small Hydro Electric Project

Tender Documents Specifications: Volume II A Civil

returned to the magazine and recorded accordingly. 309 Magazines

Khiraoganga Small Hydro Electric Project

Tender Documents Specifications: Volume II A Civil

Khiraoganga Small Hydro Electric Project

Tender Documents Specifications: Volume II A Civil

Khiraoganga Small Hydro Electric Project

Tender Documents Specifications: Volume II A Civil

Khiraoganga Small Hydro Electric Project

Tender Documents Specifications: Volume II A Civil

IS 2062 IS 4756 IS 4880

Khiraoganga Small Hydro Electric Project

Tender Documents Specifications: Volume II A Civil

Khiraoganga Small Hydro Electric Project

Tender Documents Specifications: Volume II A Civil

Khiraoganga Small Hydro Electric Project

Tender Documents Specifications: Volume II A Civil

Tech. Specifications (Civil & HM)

Tech. Specifications (Civil & HM)