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INDUS TOWERS LIMITED
Prepared By: Sadanand khodankar Approved By: Nav Ratan Mahani
Guidelines & specifications for civil & tower works
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This communication, being circulated by "Indus Towers Limited" is privileged and confidential, and is directed to and for the exclusive use of the addressee. Information contained in this communication is subject to change, at any stage, before or after the due diligence, without notice, as a part of Indus Towers Ltd. business policy. No part of this communication may be reproduced or copied in any form or by any means [graphic, electronic or mechanical, including photocopying, recording, taping, information retrieval systems, etc.] or reproduced on any disc, tape, perforated media or other information device etc. without the prior written permission of “Indus Towers Ltd”. The addressees of this communication may use this content for their own business understanding including consultants and employees. Indus Towers Ltd does not hold itself liable for any consequences, legal or otherwise, arising out of the use of any such information.
Guidelines & specifications for civil & tower works
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INDEX S.No. 1 2 3 4 5 6 7 8 Description Brief Overview Broad Expectations from Civil Vendors Guidelines & specifications for civil work Material & Quality Standards Recommended Practices at Sites Approved Laboratories for Material Testing Relevant Indian Standard Codes At a Glance Safety Instructions
Guidelines & specifications for civil & tower works
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guidelines. The document explains in detail the expectations.1. following standard processes and guidelines and ensuring timely delivery of sites. specifications. not mentioned herein. shall be treated as breach of Quality Policy and Indus reserves the right to take suitable action against concerned at its sole discretion. The document does not relieve the Civil Contractor from the responsibility of following other established civil constructions norms and processes. Brief Overview This document is primarily intended towards our esteemed business partners. The document entrusts a lot of responsibility on Civil Vendors to take care of quality of work being executed. Guidelines & specifications for civil & tower works Page 4 of 32 . or any agency authorized by Indus to do so. Our business partners are expected to go through the document carefully and ensure its compliance in true spirit. at any stage. This document is indicative only and not exhaustive. Any non-compliance observed by Indus. Compliance of this document is mandatory on the part of Civil Vendor / Contractor. executing required Civil Works for Site Built-up.
as rework increases costs & reduces profit margins. Guidelines & specifications for civil & tower works Page 5 of 32 . • Any deviation (for any reason) shall be only through written consent from SP / PMC and approval from INDUS. Quality Processes. • Vendor shall not try to influence / pressurise Quality Audit Agency in any means to compromise on the quality issues. • Quality shall be a part of system rather than treating it as a separate one. Broad expectations from Civil Vendors: • Vendors are expected to work as per INDUS Guidelines .Specifications.2. Defined SLAs. Do the works write at first time. • Quality tools can be used as cost saving tools. • Quality Assurance shall be put into the system to minimise repetition of punch points. • Not to deviate from Drawing / Design & Specifications in any situation. • Vendor to deploy a qualified engineer during project phase till site hand over to SP / Indus. • Vendor shall liquidate punch points of the Quality Audit Agency with full honour and within the stipulated timelines.
• Municipal corporation approval Guidelines & specifications for civil & tower works Page 6 of 32 . 3. For GBT sites following points to be checked while surveying the site. • See the physical site condition of the site. • Site should be located at a distance of twice the height of Indus communication tower from the high tension electrical wires.1 Site Survey For RTT sites following points to be checked while surveying the site. • Proper space for Electrical earthing should be available. • Space for material lifting should be available at site. • Proper approach road should be available to reach the material vehicles at site. • Site should be located at a distance of twice the height of Indus communication tower from the high tension electrical wires. • See the land use of the sites. • See the soil conditions. • Building should be with frame structure (RCC Columns & Beams) • Building should be with minimum 3-4 storied • Proper approach road should be available to reach the material vehicles at site. • Approved Foundation design. should not be water logged.2 Site documents to be available before starting the work • Site lay out in agreement with landlord. • Proper separate 24x7 accesses should be available.3. Guidelines & specifications for civil work 3. • Proper plot size should be available.
Birla–Chetek. loose rust and coats of paint. RATHI. Shree or ISI-marked as per approval of Engineer-incharge. oil. It will be vendor responsibility to make available all civil materials at site as per specifications and parallel check from the site civil supervisor/site engineer/civil engineer before using them.) Guidelines & specifications for civil & tower works Page 7 of 32 . L&T. Approved Brand / Make – SAIL. Approved Brand / Make : Birla-Uttam. if you feel slightly cool means it is of good quality.It should be deformed/tor bar of grade Fe415. • CEMENT (Confirm.TATA . which may destroy or reduce bond . It will also be vendor responsibility of returning back surplus material to warehouse. JK .( For all other brands prior approval is must. • Open a bag of cement and insert your hand inside. • Check for Deterioration: .3. Some Physical Rough Field-Test: • Check Mixing of Ash: -Take a certain amount of cement in your fingers and throw in a bucket of water. Grittness indicates deterioration. Vikram .KAMDHENU as per IS: 1786.ACC.Take an amount of sample and rubbing in your hands if it feels like smooth powder it means is not deteriorated. Birla Plus.3 SPECIFICATIONS OF CIVIL MATERIALS: For all materials describe below. mud or other coatings.) • REINFORCMENT STEEL— High Strength Deformed Bar (Confirm IS: 1786-1985) All reinforcement shall be free from loose mill scales.IS:269-1978) It is vendor responsibility to provide the good qualities of cement as per following specifications: • Grade of Cement: 43/53-grade Ordinary Portland Cement (OPC) unless specified otherwise.( For all other brands prior approval is must. Gujrat Ambuja.Ultra Tech. it sinks into water means it is free from any mixing of ash.
For fine works. in such quantities as to affect the strength or durability of concrete and in addition to the above. shells. organic impurities etc.. Crushed stone is not so satisfactory as natural sand since crushed stone contains a lot of the fine particles like dust. 10mm to 4. aggregate should be ordered in separate sizes and recombined in the proper proportion while batching or before batching. sand should pass through a sieve of 2mm x 2mm mesh. sharp.. sand should pass through sieve No-14 or 16BS1mm sieve.75mm.e. for reinforced concrete. • COARSE STONE AGGREGATE ( Confirm IS: 383-1970) Aggregates shall not contain any harmful material. Guidelines & specifications for civil & tower works Page 8 of 32 . clay. General Characteristics: • It should be hard. angular (gritty to touch).For RCC work it should have 20mm and for PCC 40mm nominal sizes.75mm. for concrete etc. mica and inorganic impurities. A 40mm nominal max. which require fine sand. 20mm to 10mm and 10mm to 4.• SAND / FINE AGGREGATES Fine aggregates shall consist of natural sand resulting from natural disintegration of rock and which has been deposited by streams or glacial agencies. any material which might cause corrosion of the reinforcement. coal fragments. • It should have angular or roughly cubical in shape and in no case it should be round shape. pointing etc. • It should be well graded i. For ordinary masonry work. • It should be clean. plaster. For all works it should be coarse sand except for plastering works. strong non-porous and free from laminated particles.e. hard and durable. not more than 6% except Stone Crusher sand. Note . • Aggregate sizes: . • It should be free from adherent. All sand is generally found to contain some % of silt i. or crushed stone sand or crushed gravel sand. Size aggregate will be ordered in three different— 40mm to 20mm. Size aggregate will be ordered in two different— 20mm to 10mm. such as iron pyrites. A 20mm nominal max.
sq. organic matters or other harmful substance in such amounts that may impair the strength or durability of the structure. They shall give a clean metallic sound when struck together. grout. dimensions and alignment of all parts of work and for the provision of all necessary instruments. from which all-important levels for the work will be set. acid. appliances and labor in connection therewith. Bricks broken to examine the texture shall show that they are of clean. plaster. for Class designation-105. They shall be sound. Guidelines & specifications for civil & tower works Page 9 of 32 . and free from stones and lumps.• WATER Water used for cement concrete. curing or washing of coarse aggregate shall be clear and free from injurious amounts of oil. homogeneous. The contractor shall layout one or more permanent benchmarks in some where within plot before the start the work. the contractor will be responsible to rectify the same at his own expenses to the satisfaction of the engineer-in-charge. free from more cracks. mortar. Portable water shall generally be considered satisfactory for mixing and curing of concrete. hard and well burnt with almost sharp edges. line and levels of reference and for the correctness of the levels. alkali. If at any time during the progress of work any error appears or arise in the position of levels. dimension or alignment of any part of work. • BURNT BRICKS Burnt bricks shall have a minimum compressive strength of 105Kg/cm. • SETTING OUT The contractor shall be responsible for the true proper setting out the works in relation to original points.
3. and of discharging the mixture without segregation. For hand mixing 10% extra cement shall have to be added to the normal mixes. The mixing equipment shall be capable of combining the aggregates. but where it is not possible like for roof top tower foundation or for smaller quantity. floors etc. Codes: All design and construction shall be performed in accordance with the IS code of practice for plain and reinforced concrete IS: 456. underground and over ground structures. Guidelines & specifications for civil & tower works Page 10 of 32 . curing etc of all type of cast-in-situ concrete used in foundation. The contractor has to find suitable safe place to operate the mixing machine . cement.3. sand and water within the specified time into a thoroughly mixed and uniform mass. Any special requirements as shown or noted on the drawing shall govern over the provisions of this specification. placing. The entire batch shall be discharged before recharging. The mixing period shall be measured from the time when all the solid materials are in the mixture drum.5 MIXING OF CONCRETE The mixing of concrete shall be strictly carried out in a mechanical concrete mixer. It shall be carried out on a water tight platform and care shall be taken to ensure that mixing is continued until the mass is uniform in colour and consistency. Normally.4 PCC & RCC WORK GENERAL Scope: This specification establishes the material. hand mixing can be allowed as per approval of engineer-in-charge. The mixing time in no case shall be less than two (2) minutes & shall be continued until there is a uniform distribution of materials and the mass is uniform in colour and consistency. mixing. hand-mixing of concrete shall not be permitted. provided all of the mixing water shall be introduced.
beams and similar members and shall be placed in horizontal layers not exceeding 1m deep in walls.3. as per the relevant drawings and at the direction of the Engineer-in-charge. anchor bolts. columns and similar members. • Unless otherwise approved. all equipment for mixing and transporting the concrete shall be cleaned and all debris shall be removed from the place to be occupied by the concrete. The form work should be sufficiently rigid during placing and compaction of concrete and no segregation of aggregates shall take place. Concrete shall not be done unless the form work conforms to the shapes. • Before concreting. line and dimensions as shown in drawings.6 PLACING OF CONCRETE • Before placing concrete. they should be cleaned and roughened by wire brushing & chipping. concrete shall be placed in single operation to the full thickness of slab. The bonding of old and new concrete should be done by applying the cement slurry /binding compound after thoroughly watering the old concrete surface and removing all free particles. the contractor shall provide. Guidelines & specifications for civil & tower works Page 11 of 32 . • Concrete shall be handled from the place of mixing to the place of final deposit as rapid as practicable by methods which will prevent the segregation or loss of any of the ingredients. All form and soil surfaces shall be finished to desired levels and shall be thoroughly wetted immediately prior to placing of concrete. • Concrete shall not be started unless the electrical conduits. The method of placing and compaction employed in any particular section of work shall be entirely to the satisfaction of the Engineer-in-charge. Concrete shall be placed continuously until completion of the part of work between construction joints or as directed by the Engineer-in-charge. • To ensure bond and water tightness with old concrete surface. fabricated and lay/fix in proper position all metal inserts. fan hook or any other piping wherever required are laid by the contractor. • The concrete shall in no case be dropped from a height of over 1. pipe etc.5m and it shall be carefully laid in position.
• Where concrete is placed in soil. Vibration shall not be confined only to the top surface. precaution shall be taken to see that the temperature of the wet concrete does not exceed 38-degree C while placing. it shall be placed only of firm undisturbed ground. Over vibration or vibration of mix. Vibrator shall not be allowed to come in contact with forms or finished surfaces. Care should be taken to prevent floor surface from being marred/spoiled/damaged during the curing period. the process should be completed before initial setting takes place. • Concrete shall be compacted with mechanical vibrator equipment supplemented.The whole process starting from the mixing of concrete the placing and compaction shall not take more than twenty-(20) minutes i. Any concrete that is placed on a well compacted fill shall have the prior approval of the Engineer-in-charge. 3. which have too much of water shall be avoided. • The concrete after being laid shall be compacted by means of vibrators of approved type under proper supervision as directed by the Engineer-in-charge or technical person.Care should be taken to prevent contact of vibrators against reinforcement steel. Care should be taken to avoid segregation and formation of air bubbles. The vibrator shall penetrate the layer being placed and also penetrate the layer below while the under layer still plastic to ensure good homogeneity between the two layers and prevent the formation of cold joints. Guidelines & specifications for civil & tower works Page 12 of 32 . In very hot weather. water just appearing on the surface.7 CURING Curing shall be accomplished in accordance with IS:456 by keeping the concrete covered with Jute bag or similar absorbent materials. which will be kept constantly. if necessary. wet for at least seven (7) days from the date of placing of concrete unless otherwise specified.e. to obtain consolidation then we can use hand spading and tamping also . Heavy loads shall not be placed on or moved across floor slabs until curing is complete. but the whole mass of concrete shall be well vibrated until the dense mass assume jelly like appearance and consistency. Fresh laid concrete formwork shall not be jarred/shaken.
The size of cube are 15cm x 15cm x 15cm. As per IS:456 following are the minimum values of test results after curing for 7& 28-days in respect to different concrete mix. Compressive Strength :on 15cm Cubes(N/mm. Days of curing 3 days 7 days 28 days % Compressive Strength 40% 65% 100% 3.sq. The test will be made in accordance with IS:516.NOTE: Comparative Strength of OPC at various ages.) After 28-days. 15 20 M15 10. Concrete Grade… Compressive Strength :on 15cm Cubes(N/mm.5 Guidelines & specifications for civil & tower works Page 13 of 32 . The frequency of tests shall depend upon the direction of Engineer-in-charge.0 M20 13. • Cube Test (Compression Test) Compression test is carried out to determine whether the concrete being produced complies with the strength requirements specified.8 CONCRETE TEST / OTHER CIVIL MATERIAL OR WORK TEST Sampling and testing of concrete shall be conducted in accordance with the latest issue of IS: 1199And IS: 516.sq.The sampling for the testing will be as per IS:456. Normally 7-days or 28-days tests are made on different specimens.) After 7-days.
the engineer-in-charge may require the contractor to demolish the entire structure or part thereof and reconstruct it without any claim. and any work done then INDUS Towers can go for their test ( Laboratory / Physical) from third party which will be finalized by Indus only. of cubes. 3. Care should be taken that such coating is kept free from concrete with the reinforcement. 6-Nos. good seasoned timber or other approved materials as directed by the engineer-in-charge. Guidelines & specifications for civil & tower works Page 14 of 32 .If the Engineer-in-charge is not satisfied from any materials like bricks. In case of bad concrete work. It should be sufficiently tight to prevent loss of cement slurry from the concrete. Take min.• Concrete Cube for Laboratory Test: . The inner face of the shuttering shall be cleaned and thoroughly wetted or greased with approved material.9 FORMWORK / SHUTTERING Form work for concrete in foundations/super structure shall be plywood. Under no circumstances shall the contractor attempt to cover up honeycombed concrete or otherwise attempt to camouflage/cover bad work. jute cloth or other approved materials to the satisfaction of Engineer-in-charge.The cube shall be taken at site during casting in front of site engineer. After removal of formwork the engineer-in-charge shall examine the surface of the concrete and shall give instructions for it proper finishing. cement. The stripping time for the shuttering and formwork shall be confirmed by the Engineer-in-charge as per IS:456. steel. These all test will be done as per IS code specifications. NOTE :. All joints and holes in the formwork shall be closed with putty. Formwork shall be properly designed so that it will be easy to remove and clean. sand and reinforcement steel etc.
Guidelines & specifications for civil & tower works Page 15 of 32 .3. The surface should be cleaned with brushes before application of the bitumen layer. on DPC after the concrete surface is thoroughly dry. The soak bricks shall be kept on wooden planks or back platform to avoid earth being smeared/dirty on them. The damp proof course shall be 40mm thick with cement concrete 1:2:4 (1-cement:2-coarse sand:4-12. shall be first mixed dry thoroughly and then water added and mixed to a sufficient thick consistency as required by the engineer-in-charge. 3.5mm nominal size aggregate). • Curing Masonry work as it progresses shall be kept thoroughly well watered on all faces for at least 7-days after completion.7kg/sq.m. It shall be of cement and sharp coarse sand and shall be made in small quantities so as to be used up within 30-minutes. The mortar recommended shall be of the following proportion unless mentioned. This should be mixed with water proofing compound and applying a coat of hot bitumen 1. • 1:4 for brick piers. No left over mortar shall be used. The cement and sand in required proportion. half brick wall.11 DPC AT PLINTH (1:2:4) & BITUMINOUS APPLICATION The surface has to be properly cleaned with brushes and splashed with water. • 1:5 for brick of a thickness of not less than 21cm.10 BRICK WORK IN MASONRY Brickwork shall be laid with specified mortar to be prepared in accordance with IS:2258. honey combed brickwork and hollow blocks. • Soaking of bricks Brick required for masonry in cement mortar shall be thoroughly soaked in clean water or wetted by pouring of water before use for at least 6-hours and until air bubbles cease to come out.
During this period. chicken mesh of sufficient width to extend over the uncommon material and fixed by nail before plastering is done. which appear on the surface and all portions found hollow when tapped. The joint of brickwork shall be raked out properly. wherever required shall be done by the contractor. plaster pads of about 10cm x 10cm shall be first made horizontally and vertically at not more than 2m interval over the entire surface to serve as gauges. Oil. the surface shall be cleaned with wire brush and scarified by lines with trowel or backed by chisel. junction etc. • Mortar The mortar mix shall be used at site as per mentioned in particular item of the specs agreed. Salts etc. Rounding chamfering corners. The mortar shall then be applied on the wall or the surface between the gauges and finished even.3. dirt. The thickness of plaster shall be as per specified. To ensure an even surface. • Plastering Plastering shall be started from the top and gradually worked down towards the floor. If specified in item. • Curing Curing shall start 24-hours after the plaster is laid. or are found to be soft or otherwise defective shall be cut out in rectangular shape and redone as directed by the Engineer-in-charge. It shall be kept wet for 7-days. On cement concrete surface. it shall be suitably protected from all damages at the contractor expense. The surface in both cases shall be washed properly and kept wet for 4-hours before plastering is commenced. Guidelines & specifications for civil & tower works Page 16 of 32 . Any cracks.12 CEMENT PLASTER • Preparation of surface The surface. shall be thoroughly cleaned so that it is free from dust. to be plastered.
as base course laid on the sub-base and then a finished layer of concrete or any other material. as specified. foreign matters etc.3. Care should be taken to remove all roots. It shall be watered and well rammed in layers as mentioned above and compacted to the satisfaction of the engineer-in-charge. free from vegetation and other deleterious/ harmful materials. Filling in plinth or other specified levels shall proceed in layers of 15cm along with the construction of building. proportion. the sand shall be clean. • Sub-base On the prepared bed as indicated above. to be laid. Where sand filling is specified. All the material used shall conform to the required specifications. vegetation. In case of sand filling. Care shall be taken so that there are no roots. • Preparation of bed The bed for flooring shall be prepared with level or slope as instructed by Engineer-in-charge. foreign matter etc. from the earth used for filling. The finished work shall have uniform and even surface over the whole floor or as directed by the engineer-in-charge. mixing laying curing etc for concrete shall be carried out as specified. vegetation.13 FLOORING General Flooring shall consist of a sub-base laid on the compacted earth or sand fill as required. The layer shall be beaten with hammer until thoroughly consolidated. The material for filling (earth or sand as specified) shall be brought from the source as approved by the engineer-in-charge. The materials. Guidelines & specifications for civil & tower works Page 17 of 32 . boulder or gravel or broken brick or cement concrete as specified in drawing/item as per IS:456 shall be laid to thickness as specified in drawing/items. flooding shall be done to achieve compaction if required. • Filling The surface to receive the filling shall be first cleared free of all roots. vegetation and wetted.
The surface shall be wetted with clean water before paint is applied. • Snowcem Paint It shall be done on the out side of building and boundary wall and applied 2/3-no. Curing shall be done for min 7-day. dirt. it shall be made smooth by using proper filling material over the base primer and then applied the coat of oil bound paint on it as per specified no. • Oil bound paint First coat shall be followed with base primer and if the plastered surfaces are not smooth. Cement concrete shall be placed in position with or without reinforcement as shown in drawing/as indicated in item and beaten with trowel/scuffle and finished smooth with neat cement or left rough as directed by the Engineerin-charge. All the holes and depressions should be filled with gypsum prior to application of the paint. Guidelines & specifications for civil & tower works Page 18 of 32 . • Base Course Cement concrete shall be of specified mix as indicated in drawing/item. of coats as per specified in item specs.• Sand layer The sand layer shall be spread in one or more layers to the thickness as indicated in drawing or quantity specification. 3. The colour of paint shall be indicated in item specs or as per the Engineer-in-charge. of coats. All paint should be done with the help of paintbrush only.14 PAINTING Plastered surface shall be thoroughly cleaned of dust. oil marks etc. watered and rammed. It must be up to the satisfaction level to the Engineer-in-charge. before the coat is applied. It is generally done inside the rooms. grease.
Proper slope at least 2-inches towards rain water pipe should be maintained. mud-Phuska and top with brick tilling. The following procedure shall be adopted. • Lay the brick tiles by providing 10mm joint thickness. The surface shall be thoroughly cleaned. All joints in between the sheets and at the edges near parapet should stuck to parapet & roof surface by providing adhering material bitumen. Any one of the following chemicals (as specified) in water emulsion shall be used.16 ANTI TERMITE TREATMENT (For Ground base site) It should be done as & where applicable by providing and injecting chemical emulsion for pre-constructional anti-terminated treatment and creating a chemical barrier along the external perimeter of the building and in the foundation pits before placing the PCC. scales and grease shall be removed before painting is started.45kg/sq. At joint in between the sheets. the tipping the joints with mortar mix 1:3. • The surface should be completely dry.• Synthetic Enamel Paint Synthetic enamel paint of approved brand and manufacture and of required shade shall be used for the topcoat only. All dirt.5% Page 19 of 32 Guidelines & specifications for civil & tower works . • Top surface of tile shall be finished with thick neat cement slurry. Remove the mud from the joints up to tile thickness.5% • Heptachlor emulsifiable concentrates 0. 3. hot bitumen. min 150mm overlap should be given. The surface should be perfectly dry to permit good absorption. • Lay mud-Phaska by providing proper slope towards rain water pipe with proper compaction.15 WATER PROOFING OF ROOF SLAB Water proofing treatment shall be given to the RCC roof slab by laying tar felt sheet.m all over the sheet. The paint for the under coat(base primer) shall be as recommended by the approved manufacturer. 3.5% • Aldrin emulsifiable concentrates (IS:1307-1958) 0. • Dieldrin emulsifiable concentrates (IS:1054-1962) 0. • Lay the tar felt sheet all over the roof area. • Clean the surface. • Lay a thick layer of bitumen 1.
Birla Plus. Gujrat Ambuja. Water from dewatering shall not be used. ISPAT. Guidelines & specifications for civil & tower works Page 20 of 32 . If silt / dust found in excess sand shall be washed before use. Shree.5: 3). • Brand of Cement – L&T. Minimum mixing time shall be 2 minutes • Vibrator (40mm / 60mm) shall be used for all stages • Concrete cover blocks shall be provided • Good quality steel shuttering material to be used. required.68 (34 litres / 50kg bag of cement). etc. etc. • Quality of water – Clean / potable water shall be used for concreting. dust. RATHI. PCC – M10 – 4.If available in the nearby area. Sand shall be free from silt. • Fast setting agent / compounds need to be used wherever.4. for M10 – 0.Class Bricks (105kg/cm2 strength) to be used. PCC – M10 (1: 3: 6) • Cement Qty – M20 – 8 bags / m3 of Conc. SAIL.KAMDHENU as per IS: 1786 .( As per best brand available in circles) • Concrete Mix – RCC – M20 ( 1:1. Face of shuttering shall be clean and treated with form releasing agent. Ultra Tech. dust. • Only A. • Machine Millar shall be used for concrete mixing for all stages.55 (30 litres / 50kg bag of cement). If silt / dust found in excess sand shall be washed before use • Sand / fine aggregate quality – Sand shall be free from silt. Vikram. ACC. • Quality of aggregates – Coarse / fine aggregates shall be free from organic impurities. • Life of Cement – Cement shall be used within 45 days from manufacture date • Grade of Reinforcement – Fe 415 Grade TMT Bars only • Make of Reinforcement – TATA.25 bags / m3 of Conc. Material / Quality Standards: • It is recommended to use Pre/Ready Mix Concrete for the GBT sites. • Water cement ratio – for M20 – 0. • Grade of Cement – Shall be 53 Grade (IS: 12269) OPC for RCC & 53 or 43 Grade (IS: 8112) OPC for PCC works.
• It is recommended to use pre-mixed concrete if available in nearby area. Discourage concreting in night times / poor lighted conditions • Any deviation having prior approval of Indus and SP/PMC to be marked on drawing and signed jointly by Civil Contractor & SP/PMC Engineer. exactly in the centre of the column and in water level.) shall be taken and tested at 7th & 28th days and reports submitted to client. • Civil Vendors to ensure timely intimation notice before 48 hours to SP/ PMC and INDUS. • Foundation bolts should be as per design / drawing meaning diameter. Nuts should be inserted with some friction. Incase if. • Template shall be placed as per design. Guidelines & specifications for civil & tower works Page 21 of 32 . Supports shall be provided to template bracing members in between two columns. • Non-readiness of the site from civil vendors should not happen after offering the same for inspection. length and threading length. Recommended Practices at site : 5. nuts are getting inserted easily then same should be brought in knowledge of SP/ PMC and INDUS.1 General : • Copy of Site Layout & Foundation design drawings shall be kept available at site at all times. Same to be retained in good condition and submitted alongwith bills • Minimum cover to main reinforcement shall be as per the drawing • Concrete cover blocks can be made at site in bulk. • Column alignment shall be as per drawing. • Lap / development length shall be as per drawing or atleast 45 dia. • Carry out concreting in good weather conditions only. Eccentricity is not acceptable. • Care shall be taken to avoid honey combs during concreting • No construction joint other than specified shall be permitted • Removal of formwork shall be carried out after a minimum period of 24 hrs after concreting • Concrete cube samples (raft / footing stage – 6 nos. • To ensure that checklists and pour cards are signed at all stages as specified.5. etc.
5.2 Excavation : Below is the common & ideal procedure for excavation • Layout shall be marked on ground before starting the excavation • Wooden or steel rod shall be pegged outside excavation area such that footing centre lines can be derived • Once excavation is done then line dori shall be tied between pegs and column centre points can be transferred on ground • Before putting PCC pit dimensions & pit symmetry with respect to centre lines should be verified. In exceptional cases if concreting needs to be done in night. then revised drawing shall be taken and implemented Guidelines & specifications for civil & tower works Page 22 of 32 . • Ensure column is exactly in centre of footing and there is no chance of template eccentricity • Eccentricity of base plate with respect to column centre is structurally incorrect • If any level difference in existing ground is found.3 Backfilling: • In case required depth is not achievable for any reason. proper lighting should be arranged. Bolt projections above pedestals should be thoroughly checked before taking up concreting of pedestals 5.• • • • • • • • Civil Vendors to complete excavation work before calling for inspection. Adequate chairs and spacer bars are used to hold the reinforcement in position Vibrators are not to be used continuously as per guidelines during all three stages of concreting Pedestal level difference is being checked / rectified at the time of concreting. then soil excavation shall be with reference to the lower level and the soil shall be back filled upto the top most level of natural ground level to avoid soil erosion. Concreting is to be done during day light only. PCC thickness should not be less and quality should be upto mark. Correct water cement ratio is used as per approved standards.
• Backfilling should be with proper watering and compaction. chairs. • Boulders. • Backfilling should be done in 300mm thick layers with watering and compaction.4 Reinforcement: • Reinforcement shall be bent and fixed in accordance with relevant IS Code • Reinforcement steel shall not be re-bent or straightened • All reinforcement shall be placed and maintained in position as per drawings by providing cover blocks. 5. period of 7 days in the following manner- Guidelines & specifications for civil & tower works Page 23 of 32 . Black cotton & soil with organic impurities are not to be used for back filling. 100mm high earth bund shall be made along sides and the area shall be filled with water for atleast 24 hours. spacers.• Provision of sand bed / rubble soling shall be verified from the soil consultant / foundation designer in case of marshy or clay soil • In case of dry soil with no water table. • Soil back fill shall be done in layers of 200 – 300 mm starting from centre towards the end and densely compacted and sprinkling min. • Back filling should start only after the approval of site-in-charge. 5. all foundation pits shall be soaked with water for 24 hours and compacted well prior to laying PCC • Loose pockets in foundation pits shall be completely removed and back filled with PCC • Foundation pit shall be kept dry (free from water) during laying of PCC & RCC and further for a period of 48 hours from the time of concreting • All back filling shall be done with good soil (preferably murrum) free from organic impurities and boulders. water as necessary for compaction.5 Curing: • Curing of foundations shall be carried out over a min. etc • Cross bars shall not be welded • Rough handling or dropping of reinforcement from height shall not be permitted. • After completion of back filling and compaction. In case excavated soil is black cotton / hard rock then murum should be brought from out side for backfilling.
Page 24 of 32 Guidelines & specifications for civil & tower works .• Base raft. 5. 1 litre can be applied for an area of 5 sq. • Continuous curing should be done. • Forms around base plates shall be reasonably tight to prevent leakage of the grout. Quick strength gaining – compound – CONPLAST NC – 85% strength attained in 5 days. Curing Compound – Requires no watering of surface applied for. once started. anchor bolt holes and the bottom of column base plates shall be cleaned of all oil. (Both are of FOSROC make). dirt and loose material. The use of hot strong caustic solution for this purpose will be permitted.5 litres/bag of cement. bleeding and breakdown of initial set. Grout shall be worked one side of one end to the other to prevent entrapment of air. shall be done quickly and continuously to prevent segregation. beam shall be kept continuously in damp or wet condition by ponding or covering with sacking for a minimum period of 2 days after final setting time of concrete ( 12 hrs) • Back filling shall start after 72 hrs of concreting • After completion of back filling the soil shall be kept moist/ damp/ wet condition until 7 days from concreting • Tower Erection shall start after 7 days of concreting and anchor bolt setting. • It is recommended to use any of the below mentioned curing admixtures to take additional precaution. Just spreading water at fixed intervals in a day not acceptable. the hardened concrete surfaces to be grouted shall be saturated with water. • Grouting. • Adequate clearance shall be provided between forms and base plate to permit grout to be worked properly into place. Application is by brush or spraying to concrete surface-after 60 mins (immediately after concreting) to the surface exposed to atmosphereimmediately on removal of side shuttering. • Prior to grouting. meters. grease.6 Grouting: • Surface to be grouted shall be thoroughly roughened and cleaned of all foreign matter and laitance. • Water in anchor bolts holes shall be removed before grouting is started. • Anchor bolts. Compound – CONCURE WB The strength is attained by concrete as per the normal course. Quantity – 1. Ponding and continuous watering should be done.
one of the following cementitous grouting materials can be adopted with INDUS’s approval in lieu of the above mixture. Manufacturers’ recommendation shall be followed for deciding the proportion of admixture to be used. one of the following cementitous grouting materials can be adopted with INDUS’s approval in lieu of the above mixture. or • Conbextra GP or • Degusa constructional chemical – Masterflow 918 or Page 25 of 32 Guidelines & specifications for civil & tower works . • SikaRep – Microcrete.• Below specifications shall be followed for the grouting of Tower base plate: For equal or less than 50mm thickness Cement Mortar of proportion 1:4 shall be used along with one of the following admixtures • Sika admixture – Interplast – EP&N 200 or • Fosroc admixture – Cebex 100 or • Any other tested equivalent. Manufacturers’ recommendation shall be followed for deciding the proportion of admixture to be used. • SikaRep – Microcrete. For more than 50mm thickness: Cement concrete of proportion 1:1. or • Conbextra GP or Degusa constructional chemical – Masterflow 918 or • Any other tested equivalent. Alternatively. Alternatively.5:3 (aggregate – baby chips) shall be used along with one of the following admixtures: • Sika admixture – Interplast – EP&N 200 or • Fosroc admixture – Cebex 100 or • Any other tested equivalent.
Guidelines & specifications for civil & tower works Page 26 of 32 . • Concreting during night time without proper lighting arrangement. • Eccentricity in placing column bars with respect to footing centre • Cement beyond limit (should be within 45 days of manufacture). • Non usage of mixer / vibrator. • Check nut below template should be kept at starting of the threading of the bolts. • Ensure plastering / finishing done to pedestal top and sides in line & level. Level difference should be zero. 5.7 Criteria for non acceptance of Foundation civil works • Excavated depths not achieved / done as per design drawings.• Any other tested equivalent. numbers & cutting length. etc. • Deviation in reinforcement placement in terms of size. • Base plate thickness should be seen after grouting at all sides. Template & foundation bolts placement • Template should be exactly in center of the columns. • Deviation in workmanship like mix proportions. • Punch points not attended / rectified and proceeded with work. Need to give focus on the following:• All base plate should be in one level. On top slope should be provided to prevent water stagnant around base plate. • Check nut bottom should be top of the column concrete & all columns concrete top should be in one level. • Grouting under the base plate should be done as per recommended specification. • Any other issue which is critical to the safety & quality of foundation as decided by SP / PMC / Audit Agency / INDUS. • Any stages of work carried out in absence of Audit Agency. maintaining water cement ratio. • All templates should be in one level.
Engineering collage laboratories can be used for tesing. duly received by Audit Agency. PWD.No. Other than list below.B. approved. Approved Laboratories for Material Testing Civil Contractor shall arrange 3 cube at every Concreting stage occurred during three stage inspections for GBT & two stage inspections for RTT sites for testing purposes. Approved Laboratories S. Govt. CPWD. 1 2 3 4 5 6 7 8 9 10 Name of Laboratories Thapar Engineering College Location Patiala Punjab Engineering College Chandigarh Regional Engineering College(Dr.R Ambedkar Jalandhar National Institute of Technology) Guru Nanak Dev Engineering College Ludhiana Guru Nanak Dev University/Engineering College Giani jail Singh Engineering College REC IIT Delhi College of Engineering Shriram Institute Amritsar Bathinda Kurukshetra New Delhi New Delhi New Delhi Guidelines & specifications for civil & tower works Page 27 of 32 . Civil Contractor will submit the Cubes (taken at site) Test reports (List of Approved laboratories as mentioned below) to Audit Agency in original & its copy.6.
RELEVANT INDIAN STANDARD CODES AT A GLANCE Towers are designed.M5 to M36 IS:1363-1992-part3) • Technical supply conditions for threaded steel fasteners IS:1367-1980 • Specifications for hot dip zinc coatings on structural steel and allied products IS:4759-1984 • Hexagonal bolts for steel structures IS:6639-1972 • Tolerance for fabrication of steel structures IS:7215 • Bolts shall be of 5. IS-806 • Hexagonal nuts (size range. Indus towers specified specifications are to be followed. loads and permissible stresses (sec1&2) IS:802 (Part-1)1995. manufactured. Guidelines & specifications for civil & tower works Page 28 of 32 .6 Grade as per IS:12427 For items not covered by National Specifications. erected and commissioned in accordance with relevant National Standards: • Angle Sections of structural grade IS:2062-1992/ IS:226 • Code of practice for use of structural steel in overhead transmission line towers: materials.7.
The following special symbols are used to indicate the risk of radio frequency radiation. This type of accident may be fatal or cause serious injury. SAFETY INSTRUCTIONS: Safety Instructions: “An accident may occur if the safety precautions are neglected. It may also damage the product. electrical hazards and electrostatic discharge: Guidelines & specifications for civil & tower works Page 29 of 32 .8.” For WIP sites both RTT & GBT sites proper Red colored safety indicator Tape along the periphery of site should be placed.
• Batteries can be hazardous if improperly handled. shoe and safety helmet must be used. the released power can be extremely high. All lifting devices must be tested and approved. safety belts.2 Working at Heights: When working on a mast. Special care must be used to prevent short-circuiting batteries.1 Electrical Hazards: • Direct contact with the mains power and indirect contact via damp items or moisture can be fatal. all personnel in the area must wear helmets. tower or a roof.8. “Refer to operation’s manual of a specified manufacturer. Full body safety harness. 8. • • • • • Guidelines & specifications for civil & tower works Page 30 of 32 . Adequate protective clothing is essential in cold weather. Electrolyte contains potentially hazardous material. During work on a mast. • Improper electrical installation may cause fire or electrical shock. or loss of electrolyte. • Verify that the cable markings correspond before connecting /disconnecting cable. Approved circuit breakers for the AC mains and the specified cable’s cross sectional areas must always be used. Although the battery voltage may be low.” • Short circuits can cause injury or damage. the following precautions must be taken: Personnel working at heights must have the appropriate training and medical certificate. • Only a qualified and authorized electrician is permitted to install or modify the electrical installation.
8. stones or the like.3 Safety instructions for working with Ladders: • • • • • • • • Make sure that the ladder is undamaged and has been approved for use. your navel should never be outside the edge of the ladder’s frame. outward from the ladder. two hands one foot) with the ladder when working on it. Always check that all parts of the lifting devices are intact. Give clear and consistent command signals. Free-standing ladder with a platform and knee-support. Make sure that all lifting devices are properly stabilized or attached to fixed objects such as walls or buildings before lifting. for example − lift − lower − stop Page 31 of 32 Guidelines & specifications for civil & tower works .4 Handling Heavy Goods: • • • • Use tested and approved lifting devices only. Use the ladder foot or a ladder support to reduce the risk of tipping over sideways. Always attach extension legs to a ladder that is to be used on a sloping base. and with over 2 meters height to the platform. Do not overload the ladder. Always keep 3 points of contact (two feet and one hand. Never climb the topmost four rungs of a ladder. They must only be used by trained personnel. Any other free-standing ladder longer than 3m. Extend the ladder completely. Leaning ladder longer than 5m. Climbing and using the ladder: • • • • Climb the ladder facing it. When you lean sideways. 8. Never prop up a ladder with boxes. This will reduce the risk of falling.
They can easily tip over and harm personnel. which could cause injury to personnel or damage to the equipment. Use a powder or carbon dioxide type of fire extinguisher due to the electric nature of the equipment inside the Radio Base Station. 8. Too large an angle between the lifting straps increases the strain on them and may cause them to snap. • • • • • Close the cable ducts and fire doors (if applicable) as soon as possible. Overloading. Minimize the amount of inflammable material.• • • • • Make sure that there is never an angle of more than 90_ between the straps at the point where they are attached to the lifting hook. Follow local regulations for safety clothing and safety equipment for hoisting and moving goods. Unsecured cabinets have a high center of gravity. WARNING There is a danger of the assembly toppling over. seal the cable ducts according to the regulations for the building. channels and access holes. Guidelines & specifications for civil & tower works Page 32 of 32 . Never walk under hoisted loads. can have catastrophic consequences. Avoid storing empty packaging material on the site. or wrong use of lifting devices in other ways. thereby interfering with the fire sectioning of the building.5 Fire Safety : WARNING Fire may spread to neighbouring rooms. When working on a radio base station you may have to open cable ducts. After completing work on cables.
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