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HINDUSTAN PETROLEUM CORPORATION LIMITED

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SECTION - 9

PART - A TECHNICAL SPECIFICATION FOR STRUCTURAL WORKS

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CONTENTS
CHAPTER NO. SECTION - 1 SECTION - 2 SECTION - 3 SECTION - 4 SECTION - 5 DESCRIPTION GENERAL & FABRICATION OF STEEL STRUCTURES ERECTION OF STEEL STRUCTURES ROOF, SIDE CLADDING AND GRATINGS SALIENT POINTS PAINTING OF STEEL STRUCTURES LIST OF ANNEXURES ANNEXURE - A ANNEXURE B ANNEXURE C ANNEXURE D ANNEXURE E ANNEXURE F ANNEXURE G ANNEXURE H Permissible Deviation In Pitch And Gauge Of Holes For Bolts Of Normal Accuracy Tolerance Of Assembled Components Of Steel Structures Permissible Deviation In Assembly Of Welded Joints Tolerance In Erected Steel Structures Painting System Specification For Surface Preparation With Blast Cleaning / Shot Blasting Material Of Construction List of Recommended makes / manufacturers

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SECTION-1
1.0 GENRAL

FABRICATION OF STEEL STRUCTURES

This specification shall apply to steelwork in the following buildings and general structural work.

2.0

SCOPE OF WORK LIST OF MAJOR UNITS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Tank Wagon Loading Gantry Tank Truck Filling Gantry Product Pump House (TTFG) Product Pump House(TWG) Calibration Shed Fire Water Pump House Locking & Unlocking Platform Car Parking Shed & VIP Car Parking Shed Watch Tower (8 Nos.) Dosing Shed for Power & Turbo Dosing Shed for Marker & Blue Dye Swing Platform Foam Tank Shed (5 Nos.) Pipe Bridge between two TTFG Pipe Bridge between TTFG & Pump House R.O.Plant DG Sheds (Yard)

2.1

The scope of work under fabrication includes, but not limited to, the following: a) b) Preparation and submission of material indents, bolt lists and bought-out items list. Procurement and collection of all steel materials, Colour coated sheets, polycarbonate sheets, Translucent sheets, MS gratings, Gutters & pipes from stockyards/stores, including packing, loading, transportation and supply at site, unloading, stacking & storing on skids or supports at site.
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c)

Procurement and supply of all consumables like bolts, nuts, hooks, Polycoated hook bolts, washers, electrodes, paints, shims, packs, etc., taking into consideration allowance for spares and wastage. Preparation and submission of fabrication drawings, assembly drawings for Steel Structures, sheeting/gratings, modification /rectification sketches, erection drawings, as-built drawings, bill of materials, bolts lists and shipping documents for approval of purchaser. Submission of design calculation for non-standard connections, temporary bracings etc. for approval of purchaser. Cold straightening of section and plates, whenever they are bent and kinked. Fabrication of all steel structural components covered under design drawings including gratings and generally described under the scope of the project. Making arrangements for and conducting tests, such as chemical analysis, physical and mechanical tests on raw materials where specified/as directed by the Purchaser/Consultant. The scope of testing includes conducting tests at shop as well as at site in line with the instruction of Purchaser/Consultant. Making arrangements for providing all facilities for conducting ultrasonic, X-ray or gamma ray tests of welds; getting the tests conducted by reputed testing laboratories making available test films / graphs, reports and interpretation. The scope of testing includes conducting tests at shop as well as at site in line with the instruction of Purchaser/Consultant. Controlled Assembly of steel structural components at shop, wherever required. Preparation of steel structural surfaces for painting as provided in the specifications / drawings. Application for one primer coat of painting at shop, as specified in the design drawing/specifications. Loading, transportation from fabrication workshop to site of erection and unloading of all steel structural components / units / assemblies, Colour coated sheeting, MS gratings or any other grating and their erection complete with all fittings and fixtures.
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d)

e)

f) g)

h)

i)

j) k)

l)

m)

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n)

Rectification of damaged structures including fixing, aligning, leveling, bolting and welding etc. Preparation of "As-built" drawings.

o)

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3.0

PREPARATION OF FABRICATION AND ERECTION DRAWINGS

3.1 3.2

Fabrication drawings shall be prepared based on design drawings of steel structures. Drawing shall be prepared in metric system as per IS: 813-1986. The fabrication drawings shall specify the following details: (a) Type, size and length of welds in case of welded connections,(specifying clearly shop or site weld). Length of weld specified shall be effective length (excluding end crates). In case of bolted joints, arrangement of bolts and specification of bolts, nuts etc. (specifying clearly shop and site bolts). Specification of electrode/wire flux. If required special provision to be mentioned in the drawings for handling of structures during and after fabrication. Specification of paint and corresponding surface preparation for painting. General arrangement/marking plan. Reference to design drawings. Material list indicating mark number-wise material requirement giving size, weight, material specification, identification number of each items, number of pieces required etc. Layout with all connecting members with blown up joint details wherever required, in order to specify clearly various fabrication and erection requirements as per design drawings. Specification of preparation of mating surfaces in case of connection by HSFG bolts. Appropriate edge preparation in case of butt/groove welds in accordance with IS: 9595-1996, for all plates and sections having thickness greater than 8 mm.
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(b)

(c) (d)

(e) (f) (g) (h)

(i)

(j) (k)

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(l)

Erection clearances in order to facilitate smooth erection at site (ref clause no.11.2.2.of IS: 800- 2007).

(m) Each erection piece shall be clearly identified by an erection mark in these drawings. All loose members shall be given part mark, which shall be 'wired on' the main erection piece for despatch. 3.3 Fabrication drawings shall be prepared in such a manner that structures can be despatched from fabrication shop to erection site with maximum economic transportable size, so as to reduce work involved at site to a minimum. Bracings shall be connected for 50% of the capacity of the member or the force specified in the design drawing, whichever is more.(for single angle bracing member, consider full area as effective for this purpose). Standard simple beam connections, unless otherwise stated in the drawings, shall be designed and detailed for 60% beam shear / moment carrying capacity. Wherever there is risk of nuts becoming loose due to vibration, lock nuts shall be provided, or nuts shall be welded after alignment and tightening. For all connections by permanent bolts, two nos. of washers shall be used. One washer bearing against the head and the other bearing against the nut. Detailing of structural steel members subject to dynamic loading shall be such as to ensure smooth transition of load, as well as best behaviour under stress due to fatigue. For detailing connection, the allowable stress for materials, welds, bolts etc, shall be as per IS:800- 2007 and IS:816-1969, or as specified in the drawing. The contractor shall be responsible for design and detailing all connections. The design of connection shall provide adequate strength for transfer of force in the structural elements, as indicated on design drawings. Detailing shall be such that erection shall be convenient and free from all interfaces, drilling and cutting at site.

3.4

3.5

3.6

3.7

3.8

3.9

3.10

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4.0 4.1

MATERIALS Structural Steel Structural steel and other related materials for construction shall conform to ANNEXURE-G.

4.1.2

Due to non-availability of specified materials, suitable substitutions may be provided with the consent of the purchaser. Such substitution shall be incorporated in the "As-built" drawings. All the items are to be cut as per requirements of the drawing. If joints are to be provided in any item, in order to meet requirements of size and shape, cutting plan showing locations of joints shall be prepared for consideration of purchaser. Joints provided shall be incorporated in "As-built" drawings. Rolling and cutting tolerances shall be as per IS: 1852:1985. Only tested materials shall be used unless use of untested materials for certain secondary structural members is permitted by purchaser. If test certificate for the material is not available from the main producer, the following tests shall be carried out at the discretion of the purchaser. (a) Chemical Composition (b) Mechanical Properties (c) Weldability test

4.1.3

4.1.4 4.1.5

4.1.6 4.2 4.2.1 4.2.2

Where steel castings are to be used the same shall conform to IS: 1030:1998. Bolts and Nuts Black hexagonal bolts, nuts and lock-nuts shall conform to IS: 1363:2002. Precision and semi-precision hexagonal bolts, screws, nuts and lock-nuts shall conform to IS: 1364:2002.

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4.2.3

High tensile friction grip bolts shall conform to IS: 3757:1985 and high strength structural nuts shall conform to IS: 6623:2004, and hardened steel washers to IS: 6649:1985. Electrodes Mild steel electrodes and high tensile steel electrodes shall conform to IS: 814:2004. Electrode to be used for submerged arc welding shall conform to specification IS: 7280:1974. STORING OF MATERIALS Materials shall be stored and stacked properly ensuring that place is properly drained and is free from dirt. It shall be ensured that no damage is caused due to improper stacking. MATERIAL PREPARATION Cut edges shall be finished smooth by grinding or machining wherever necessary. Sufficient allowance (3 mm to 5 mm) should be kept in the items incase machining is necessary. Cutting may be effected by gas cutting, shearing, cropping or sawing. In gas cutting of high tensile steel, special care is to be taken to leave sufficient metal to be removed by machining so that all metal that has been hardened by flame is removed. Sufficient shrinkage allowance (@ 1mm/M) shall be kept wherever heavy welding is involved. Straightening and bending shall be done in cold condition as far as practicable. If required, straightening and bending may be done by application of heat between 900C and 1100C. Cooling down of the heated item shall be done slowly. DRILLING AND PUNCHING OF HOLES Drilling and punching of holes for bolts shall be done as per clause no.11.2.4 of IS: 800:2007, unless otherwise specified by the purchaser.

4.3 4.3.1

5.0 5.1

6.0 6.1

6.2

6.3

6.4 6.5

7.0 7.1

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7.2

Drifting of holes for bolts during assembly shall not cause enlargement of holes beyond permissible limit or damage the metal. Holes for bolted connection should match well to permit easy entry of bolts. Gross mismatch of holes shall be avoided. Permissible deviation in holes for mild steel bolts of normal accuracy and high strength bolts are given in the ANNEXURE-A.

7.3

7.4

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8.0 8.1

ASSEMBLY FOR FABRICATION Fabrication of all structural steelwork shall be in accordance with IS: 800-2007 and in conformity with various clauses of this specification, unless otherwise specified in the drawings. Fabrication of structures shall preferably be taken up as per the sequence of erection. All erection units shall bear erection mark no. and reference drg no. at a prominent location on the structures for easy identification at site. Fabricated structures shall conform to tolerance as specified in this standard and in IS: 7215-1974. In case of contradiction, tolerances specified in this standard shall prevail. All the components of structures shall be free from twist, bend, damage etc, Assembly of structures shall be carried out by using suitable jigs and fixtures in order to obviate distortion during welding. Cutting of items specially for truss, bracing, portal etc, shall be done only after checking of sizes as per Layout. Surface, wherever machining is specified, shall be either planed or milled or ground to ensure maximum contact. If end-milling or machining is planned after the assembly is over, sufficient allowance (5 mm to 15 mm) shall be kept in the items where milling/machining is to be done. If pre-bending of the plate is required to avoid welding distortion, it shall be done in cold condition. If extra joints are required to be provided in column etc, approval should be obtained from the purchaser. However, as general guidance following is suggested. Splice joints of column shall of full strength butt weld and wherever possible shall be located at zones of minimum or substantially lesser stress. Splice joints of flange and web should preferably be staggered. Sufficient trial assembly of fabricated components (despatch elements) shall be carried out in the fabrication works to control the accuracy of workmanship.
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8.2 8.3

8.4

8.5 8.6

8.7

8.8

8.9

8.10

8.11

8.12 8.13

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8.14

Where necessary, washers shall be tapered or otherwise suitably shaped to give the heads of nuts and bolts satisfactory bearing. The threaded portion of each bolt shall project through the nut at least by one thread. Tolerance of assembled components of structures are given in ANNEXURE-B. Permissible deviations from designed (true) geometrical form of the despatch elements shall be in accordance with IS: 7215-1974.

8.15 8.16 8.17

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9.0

WELDING

9.1

The Contractor shall work out welding procedure for Purchaser's approval, considering the following factors: (i) (ii) (iii) Specification and thickness of steel. Specification of electrode or/and base wire. Welding process (manual arc welding, submerged arc welding).

(iv) Type of structures to be welded (thickness of components meeting at a joint). (v) Pre and post heating requirement.

(vi) Preparation of fusion faces. (vii) Sequence of welding. (viii) Weather condition. (ix) (x) Use of jigs and fixtures etc. Type of non-destructive testing to be carried out.

(xi) Inspection procedure to be followed (xii) Design requirements of the joints. 9.2 Welding of any load bearing structure shall be carried out only by the person who has passed welder's qualification as per IS: 7318 (Part-I) -1974. All metal arc welding shall be carried out as per IS: 9595-1996. Submerged arc welding of mild steel and low alloy steel shall be as per IS: 4353-1995 Electrode shall conform to clause no.4.3 of this standard. Electrodes shall be stored in a dry place. Electrodes whose coatings are damaged due to absorption of moisture or due any other reason shall not be used.
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9.3 9.4 9.5 9.6

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9.7

Low Hydrogen electrodes and flux for submerged welding shall be dried at 250-300 C for one hour in drying even before use. For suitability of wire flux combination, procedure test shall be carried out as per IS: 3613-1974 if so required. Welding shall be done by electric arc process. Generally submerged arc, automatic & Semi-automatic welding shall be employed. Only where it is not practicable, manual arc welding may be resorted to. In case of manual arc welding, recommendations of electrode manufacturer is to be strictly followed. Welding surface shall be smooth, uniform, free from fins, tears notches or any other defect which may adversely affect welding. For multi-run weld deposit, the next run should be done only after thorough removal of slag and proper cleaning of surface. Fillet weld shall have the correct profile with smooth transition into parent metal. Dressing of welds, if specified, shall be done by such method which does not cause grooving and other surface defects on the weld or on the parent metal. All butt welds shall start and end with run-on and run- off plates. All such plates shall be carefully trimmed off by gas cutting after welding is over. Fillet welds shall not be stopped at corners but shall be returned round them. If butt weld is to be ground flush with the surface of the member as per drawing. adequate reinforcement shall be built up and then the same shall be chipped off and ground flush. The grinding is to done in the direction of stress flow till the transverse marks are eliminated. Welding shall not be done under such weather conditions which might adversely affect the efficiency of the welding. Manipulators shall be used wherever necessary and shall be designed to facilitate welding and ensure that all welds are easily accessible to the operators.

9.8

9.9

9.10

9.11

9.12

9.13

9.14 9.15

9.16

9.17

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9.18

Stress relieving after welding shall be done if especially called for in the drawing or specification. Ends of structural members and portions of gussets receiving welding at site, shall be left unpainted. Permissible deviation in assembly of weld joints shall be in accordance with ANNEXURE - C.

9.19

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10.0 10.1

INSPECTION & TESTING The purchaser/Inspector shall have free access at all times to those parts of Contractor's or his Sub- Contractor's works which are concerned with the fabrication of steel works and shall be afforded all reasonable facilities at all stages of preparation, fabrication and trial assemblies for satisfying himself that the fabrication is being undertaken in accordance with the provisions of relevant specification. All gauges and templates, tools, apparatus, labour and assistance for checking shall be supplied by the contractor free of charge. The purchaser /Inspector may at his discretion, check the test results obtained at the Contractor's works, by independent test at the Government Test House or elsewhere, and should the material so tested be found to be unsatisfactory, the cost of such such test shall be borne by the Contractor. Contractor shall make all necessary arrangements for stage inspection by purchaser/Inspector during the fabrication at shop and incorporate all on-the-spot instructions / changes conveyed in writing to the Contractor. Material improperly detailed or wrongly fabricated shall be reported to the Purchaser/Inspector and shall be made good as directed. Minor misfits which can be remedied by moderate use of drift pins, and moderate amount of reaming and slight chipping may be corrected in that manner, if in the opinion of the Purchaser/Inspector the strength or appearance of the structure will not be adversely affected. In the event the Purchaser/Inspector directs otherwise, the items will be rejected and a completely new piece shall be fabricated. The cost of correcting errors shall be to the account of the Contractor.

10.2

10.3

10.4

10.5

i) The Purchaser/Engineer shall have the power: a) To certify, before any structure is submitted for inspection, that the same is not in accordance with the contract, owing to the adoption of any unsatisfactory method of fabrication. To reject any structure as not being in accordance with specifications & drawings. To insist that no structure or parts of the structure once rejected is resubmitted for inspection/test, except in cases where the Purchaser / Inspector authorised representative considers the defects as rectifiable.
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b)

c)

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ii)

If, on rejection of structure by the Purchaser/Inspector the Contractor fails to make satisfactory progress within the stipulated period, the Purchaser/Inspector shall be at liberty to cancel the contract and fabricate or authorise the fabrication of the structures at any other place he chooses, at the risk and cost of the Contractor, without prejudice to any action being taken in addition to terms of General Conditions of Contract. The Purchaser / Inspector's decision regarding rejection shall be final and binding on the Contractor. The specifications prescribe various tests at specified intervals for ascertaining the quality of the work done. If the tests prove unsatisfactory, Purchaser/Inspector shall have liberty to order the Contractor to re-do the work, done in that period and/ or to order such alterations and strengthening that may be necessary at the cost of the Contractor and the contractor shall be bound to carryout such orders failing which the rectification/redoing will be done by the Purchaser through other agencies and the cost recovered from the Contractor. Notwithstanding any inspection at the workshop the Purchaser/Inspector shall have the liberty to reject, without being liable for compensation any fabricated members or materials brought to site that do not conform to specifications / drawings. All rejected materials shall be removed from the site of fabrication by the Contractor at his own cost and within the time stipulated by the Purchaser/Inspector.

iii)

iv)

v)

vi)

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11.0

CONTROLS IN WELDING

11.1

The extent of quality control in respect of welds for structural elements for both statically and dynamically loaded structures shall be as follows and shall be conducted by the contractor at his own cost:a) Visual Examination - All welds shall be 100% visually inspected to check the following: i) Presence of undercuts ii) Visually identifiable surface cracks in both welds and base metals. iii) Unfilled craters iv) Improper weld profile and size v) Excessive reinforcement in weld vi) Surface porosity Before inspection, the surface of weld metal shall be cleaned of all slag, spatter matter, scales etc. by using wire brush or chisel. b) Dye Penetration Test (DPT) This shall be carried out for all important fillet welds and groove welds for both statically and dynamically loaded structures to check the following: i) Surface cracks ii) Surface porosities Dye Penetration Test shall be carried out in accordance with American National Standard ASTM E165.

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c) Ultrasonic testing Ultrasonic test shall be conducted for all groove welds and heat affected zone in dynamically loaded structures and for other important load bearing butt welds in statically loaded structures as desired by purchaser, to detect the following: i) Cracks ii) Lack of fusion iii) Slag inclusions iv) Gas porosity Ultrasonic testing shall be carried out in accordance with American National Standard ANSI/AWS D1.1-96 Chapter -6: Part F. Before ultrasonic test is carried out, any surface irregularity like undercuts, sharp ridges etc. shall be rectified. Material surface to be used for scanning by probes must allow free movement of probes. For this purpose, surface shall be prepared to make it suitable for carrying out ultrasonic examination. d) Radiographic Testing (X-ray and Gamma-Ray Examination) :- This test shall be limited to 2% of length of welds for welds made by manual or semi- automatic welding and 1 % of length of weld if made by automatic welding machines . The location and extent of weld to be tested by this method shall be decided by purchaser to detect the following defects: i) Gas porosity ii) Slag inclusions iii) Lack of penetration iv) Lack of fusion v) Cracks

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Radiographic testing shall be conducted in accordance with American National Standard ANSI/AWS D1.1-96 Part E. Any surface irregularity like undercuts, craters, pits etc. shall be removed before conducting radiographic test. The length of weld to be tested shall not be more than 0.75 x focal distance. The width of the radiographic film shall be width of the welded joint plus 20 mm on either side of the weld.

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12.0 12.1

ACCEPTABLE LIMITS OF DEFECTS IN WELD Limits of Acceptability of welding defects shall be as follows: a) Visual inspection & Dye Penetration Test - The limits of acceptability of defects detected during visual inspection and Dye Penetration Test shall be in accordance with clauses 6.9 & clause 6.10 of American National Standard ANSI/AWS D1.1-96 for statically as well as dynamically loaded structures respectively. Ultrasonic Testing - The limits of acceptability of defects detected during ultrasonic testing shall be in accordance with clause 6.13.1 & clause 6.13.2 of American National Standard ANSI/AWS D1.1-96 Chapter 6: Part C for statically and dynamically loaded structures respectively. Radiographic testing - The limits of acceptability of defects detected during Radiographic testing shall be in accordance with clauses 6.12.1 & 6.12.2 of American National Standard ANSI/AWS D1.1-96 Chapter 6: Part C for statically and dynamically loaded structures respectively.

b)

c)

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13.0 13.1

RECTIFICATION OF DEFECTS IN WELDS In case of detection of defects in welds, the rectification of the same shall be done as follows: i) All craters in the weld and breaks in the weld run shall be thoroughly filled with weld. Undercuts, beyond acceptable limits, shall be repaired with dressing so as to provide smooth transition of weld to parent metal. Welds with cracks and also welds with incomplete penetration, porosity, slag inclusion etc. exceeding permissible limits shall be rectified by removing the length of weld at the location of such defects plus 10 mm from both ends of defective weld, and shall be re-welded. Defective weld shall be removed by chipping hammer, gouging torch or grinding wheel. Care shall be taken not to damage the adjacent material.

ii)

iii)

14.0 14.1

ACCEPTANCE CRITERIA OF MACHINING SURFACE Standard of acceptance for machined surfaces, wherever specified by designer, (eg. in column cap plates, base plates and column shafts etc.)shall be as given as per clause 14.2 & 14.3. Maximum surface unevenness on bearing surface of cap/ base plate shall not exceed 0.5 mm. When assembled, there must be physical contact for at least 75% of the contact surface.(The checking shall be carried out with 0.2mm guage. Care should be taken that these connecting members are fixed with such accuracy that they are not reduced in thickness during machining by more than 1.0 mm.

14.2

14.3

15.0

DESPATCH INSTRUCTIONS Each despatchable structure shall bear mark no. along with reference drawing number at two prominent locations (e.g. on flange and bottom of base plate of a column).

15.1

"As built" drawing shall be prepared after fabrication is completed to indicate additions / alterations made during the process of fabrication. (Refer clause 4.1.2 & 4.1.3.)
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15.2

Control assembly of important structures shall be done in the shop floor before despatch to avoid mismatching. For all such important structures, match marking shall be given at the control assembly stage in the shop floor and such match markings shall be made clearly visible while assembling the structures at site. Centre lines of column flanges and both sides of web shall be punched, preferably at top and bottom to facilitate alignment after erection.

15.3

16.0 16.1

COMPLETION DOCUMENTS On completion of work, the Contractor shall submit to the Purchaser the following documents: a) b) The technical documents according to which the work was carried out. Copies of the As built" drawings showing thereon all additions and alterations made during the fabrication. Manufacturers test certificates Certificates/documents on control checking Test of welds

c) d) e)

f) Inspection Certificates issued by Purchaser/Consultant for the material/structures.

17.0

In addition to provision of erection and transport equipments, the scope of work includes supply of tools and tackles, consumables, materials, labour and supervision and shall cover the following: a) Storing and stacking of all fabricated structural components/units/assemblies at site storage yards till the time of erection. b) Transportation of structures from storage yard to site of erection, including multiple handling, if required.

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c) All minor rectification / modifications such as: i) Removal of bends, kinks, transportation and handling. twists etc. for parts damaged during

ii)

Reaming of holes which do not register or which are damaged, for use of next higher size bolt. Plug-welding and re-drilling of holes which do not register and which cannot be reamed for use of next higher size bolt. Drilling of holes which are either not drilled at all or are drilled in incorrect position during fabrication.

iii)

iv)

d) Fabrication of minor missing items as directed by the purchaser. e) Verification of the position of embedded anchor bolts and inserts w.r.t. line find levels, installed by others based on Geodetic Scheme / Bench mark / Reference co -ordinates to be furnished by the Purchaser. f) Assembly at site of steel Structural components wherever required, including temporary supports and staging. g) Marking arrangements for providing all facilities for i) Conducting ultrasonic x-ray or gamma ray tests by reputed testing laboratories Making available test films / graphs, with reports / interpretation.

ii)

h) Site Rectification of damaged portions of shop primer by cleaning and application touch-up paint. i) Erection of structures including making connections by bolts / High strength Friction Grip bolts/welding as per drawing. j) Alignment of all structures true to line, level plumb and dimensions within specified limits of tolerance. k) Application at site after erection, required number of coats of primer and finishing paint as per specification and drawing.
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l) Rectification of structures as per Preliminary acceptance report and Final acceptance report. 18.0 18.1 STORING AND HANDLING Storage of structures shall be preferably be done in such a manner that erection sequence is not affected. While storing, care shall be taken so that structures do not come in direct contact with the earth surface and accumulated water. Girders, beams, columns. shall be placed and stored in such a manner that during rain, no accumulation of water on the structures takes place. Stacking of the structures shall be done in such a way that, erection marks are visible easily and handling does not become difficult. Wherever required, wooden sleepers / grilles may be used. Handling and storage of materials shall be as per IS: 7969-1975, to ensure safety.

18.2

18.3

18.4

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SECTION 2
19.0 19.1 19.1.1 ERECTION General

ERECTION OF STEEL STRUCTURE

Erection shall be carried out in accordance with IS: 800:2007 and other relevant standards referred to therein. For safe and accurate erection of structural steelwork, staging, temporary support, false-work etc. shall be erected as required. The fabricated materials received at erection site shall be verified with respect of marking on the key plan/marking plan or shipping list. Any material found damaged or defective shall be stacked separately and the damaged or defective portions shall be painted in distinct colour for identification and the same shall be brought to the notice of the Purchaser. Erection Drawings The approved erection drawings and any approved arrangement drg, specification or instruction accompanying them shall be followed in erecting structures. Erection of Structures Erection work shall be taken up after receipt of clearance from the purchaser. For safety requirements during erection, provisions in IS: 7205:1974, IS: 7969:1975 and other relevant Indian standards shall be followed. Erection shall be carried out with the help of maximum mechanization possible. Prior to commencement of erection, all the erection equipment, tools, tackles, ropes etc. shall be tested for their load carrying capacity. Such tests may be repeated at intermediate stages also if considered necessary and frequent visual inspection shall be done of all vulnerable areas and components to detect damages or distress in the erection equipment, if any.
SECTION 9 (PART A) 1 Page 26 of 58 2010 MECON LIMITED. All rights reserved MEC/23KM/T-25/10000012

19.1.2

19.1.3

19.1.4

19.2 19.2.1

19.3 19.3.1 19.3.2

19.3.3 19.3.4

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19.3.5

Following shall be taken care of during erection, whenever necessary:-

19.3.5.1 Temporary bracing, whenever required, shall be provided to sustain forces due to erection loads and equipment etc. Erected parts of the structures shall remain stable during all stages of erection when subjected to the action of wind, dead weight and erection forces etc. Specified sequence of erection of vertical and horizontal structural members shall be followed. 19.3.5.2 Erected members shall be held securely in place by bolts to take care of dead load, wind load and erection load. 19.3.5.3 All connections shall achieve free expansion and contraction of structures wherever provided. 19.3.5.4 No final bolting or welding of joints shall be done until the structure has been properly aligned. 19.3.5.5 For positioning beams, columns and other steel members, the use of steel sledges is not permitted. 19.3.5.6 Instrumental checking of correctness of initial setting out of structures and adjustment of alignment shall be carried out in sequence and at different stages as required. The final leveling and alignment shall be carried out immediately after completion of each section of a building. 19.3.5.7 All structural members shall be erected with erection marks in the same relative position as shown in the appropriate erection and shop drawings. The contractor shall design, manufacture, erect and provide false-work, staging temporary support etc. required for safe and accurate erection of structural steelwork and shall be fully responsible for the adequacy of the same. 19.3.5.9 The Contractor shall also provide facilities such as adequate temporary access ladders, gangways, tools & tackles, instruments etc.to purchaser for his inspection at any stage during erection.

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19.4 19.4.1

Field Connections Assembly by permanent bolts.

19.4.1.1 The numbers of washers on permanent bolts shall not be more than two (and not less than one) for the nuts and one for the bolt head. 19.4.1.2 Wooden rams or mallet shall be used in forcing members into position in order to protect the metal from injury or shock. 19.4.1.3 Where bolting is specified on the drawing, the bolts shall be tightened to the maximum limit. The threaded portion of the each bolt shall be project through the nut by at-least one thread. Tapered washers shall be provided for all heads and nuts to achieve uniform bearing on sloping surface. 19.4.1.4 To prevent loosening of nuts, spring washers or lock- nuts shall be provided as specified in the design/shop drawings. 19.4.1.5 All machine-fitted bolts shall be perfectly tight and the ends shall be checked to prevent nuts from becoming loose. No unfilled holes shall be left in any part of the structures. 19.4.2 Assembly by welding

19.4.2.1 All field assembly by welding shall be executed in accordance with the requirements for shop fabrication. Where the steel has been delivered painted, the paint shall be removed before field welding for a distance of at least 50 mm on either side of the joints to be welded. 19.4.2.2 All other requirements in welding shall be in accordance with clauses specified under Section-1 of this specification 19.4.3 Assembly by High Strength Friction Grip Bolts (HSFG) 19.4.3.1 Assembly of structures with HSFG bolts shall conform to IS: 4000-1992. 19.4.3.2 The mating surfaces shall be prepared in accordance with the requirements of design in order to achieve required properties to develop adequate friction between the surfaces. 19.4.3.3 The mating surfaces shall be absolutely free from grease, lubricant, dust, rust etc. and shall be thoroughly cleaned before assembly.
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19.4.3.4 The nuts shall be tightened up-to the specified torque with the help of torque -wrench or by half- turn method with the help of pneumatic wrench lever. 19.4.3.5 The direction of tightening of the nuts shall be from the middle toward the periphery of assembly. 19.4.3.6 After desired tightening the bolt heads, nuts and edges of the mating surfaces shall be sealed with a coat of paint to obviate entry of moisture.

20.0 20.1

ACCEPTANCE STANDARD OF WELDING Acceptance standard of welding shall be as specified in SECTION-I of this specification.

21.0 21.1

BEDDING AND GROUTING Base plates shall be set to elevations shown on the drawings, supported aligned and leveled using steel wedges and shims or by other approved methods. Plates shall be leveled properly, positioned and the anchor bolts tightened. Bedding/grouting shall be carried out until sufficient number of columns have been properly aligned, leveled and plumbed and sufficient number of girders, beams, trusses and bracings have been put in position to the satisfaction of purchaser.

21.2

22.0

PAINTING OF STEEL STRUCTURES Refer to SECTION-5.

23.0

ERECTION TOLERANCES Maximum permissible tolerances in erected steel structures shall be as given in ANNEXURE-D.

Tenderers Signature with seal: Date:

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24.0 24.1

ACCEPTANCE OF WORK Acceptance of erected steel structures shall be either after completion of erection of the whole building or in blocks. Preliminary acceptance certificates will be given in the following cases:i) ii) Any steelwork or part thereof embedded in concrete. Steel structures, which are to be covered in the process of carrying out further work.

24.2

25.0 25.1

DOCUMENTATION The following documents shall be prepared at the time of acceptance of erected structures. i) ii) iii) iv) Documents showing actual deviations made during execution of erection work and approval of competent authority. Documents showing acceptance of embedded structures. Certificate/documents on control checking and test of materials (if any) and weld. Data and result of geodetic measurements obtained while checking the erection of the structures.

25.2

Copies of "As-Built" drawing showing thereon all additions and alternations which took place between approval of drawing and erection of structures.

Tenderers Signature with seal: Date:

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SECTION-3

ROOF AND SIDE CLADDING WITH COLOUR COATED TROUGHED GALVANISED STEEL SHEETS (GCS)

26.0

Roof sheeting shall be of Hi-Rib profiled colour coated Galvalume / Zincalume BHP ULTRA Steel sheet made of cold rolled steel of 550 MPA minimum yield strength conforming to ASTM A 366 or AS 1595 with hot dip metallic coating of minimum 200 gm/sq.m zinc-aluminium alloy coating mass (55% Aluminium, 43% zinc and 1.5% silicon), total of both sides as per ASTM A 792 or AS 1397. Base metal thickness shall be 0.6 mm. Total thickness of colour coated profiled sheet shall be 0.68 mm. The colour shall have a total coating thickness of 40 microns of paint system as per AS/NZS-2728:1997 of approved colour comprising of 20 microns exterior coat on top surface and 10 microns reverse coat on back surface over 5 microns primer coat on both surfaces (color bond ultra steel quality paint coat or equivalent). Sheeting shall be fixed to the purlins for the full thickness of purlin top flange with extra projection of 5 to 10 mm below flange with wafer head self drilling zinc coated (40 microns hot dipped) fasteners of approved make. All screws shall pass through the crown of the Hi-Rib of the roof sheeting. The side laps shall also be fixed withself drilling zinc coated fasteners of approved make. Flashing, Cappings, Ridge etc., shall be of 0.68 mm plain colour coated Galvalume / Zincalume BHP steel sheet with necessary fasteners. Translucent sheets (FRP) of thickness 2 mm at specified locations to match with the corrugations of Hi-Rib profiled colour coated galvalume / zincalume BHP steel roof sheets, shall conform to IS:12866-1989(FRP) WALL CLADDING: Wall cladding shall be of Hi-Rib profiled colour coated Galvalume / Zincalume BHP ULTRA steel sheet made of cold rolled steel of 550 MPA minimum yield strength conforming to ASTM A 366 or AS 1595 with hot dip metallic coating of minimum 200 gm/sq.m zinc-aluminium alloy coating mass (55% Aluminium, 43% zinc and 1.5% silicon), total of both sides as per ASTM A 792 or AS 1397. Base metal thickness shall be of 0.6 mm. Total thickness of colour coated profiled sheet shall be of 0.68 mm. The colour shall have a total coating thickness of 40 microns of paint system as per AS/NZS-2728:1997 of approved colour comprising of 20 microns exterior coat on top surface and 10 microns reverse coat on back surface over 5 microns primer coat on both surfaces (colorbond ultra steel quality paint coat or equivalent). Cladding sheets shall be of valley fixed to wall runner with hot dip galvanised self drilling fasteners with integral EPDM/neoprene washers of approved make. Also

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fasteners to be provided on side laps. Minimum sheet overlap at end laps shall be of 150 mm. Flashing, Cappings,etc., shall be of 0.68 plain colour coated Galvalume / Zincalume BHP steel sheet with necessary fasteners. Translucent sheets (FRP) of thickness 2 mm at specified locations to match with the corrugations of Hi-Rib profiled colour coated galvalume / zincalume BHP steel sheets, shall conform to IS:12866-1989(FRP) 27.0 ROOF AND SIDE CLADDING WITH COLOUR COATED TROUGHED STEEL SHEETS / POLY CARBONATED SHEETS The scope of work shall cover: a) Preparation of drawings showing layout and size of sheets used, details of connections and flashings, bill materials. Procurement and supply of sheets of all gauges and sizes, flashings and fittings like corner pieces, apron pieces, ridges, cutting and bending of sheets wherever required; drilling of holes all as per specification, drawings and fixing with the purlins as per manufacturer recommendations to make full water proof & to withstand against wind load. Procurement and supply of Galvanised Hex self drilling tapping screws and EPDM/neoprene washers. Loading, transportation, unloading and delivery of sheeting material from place of procurement to erection site. Provision of all tools, tackles, equipment. labour supervision and services required for the satisfactory completion of the work specified herein and on the drawings. Erection in position sheets for roofing, walling, louvres; erection of all flashings, fittings like ridges, valleys, gutters, corners, apron etc. at all locations all work as per drawings and specifications.

27.1

b)

c)

d)

e)

f)

27.2.

All necessary galvanised flashings, ridging, capping, gable and corner trimming shall be made from same material and in line with the gauge of roof/side covering where it is used. Where connection between two different gauge sheetings is involved thickness corresponding to lower gauge may be used.
SECTION 9 (PART A) 1 Page 32 of 58 2010 MECON LIMITED. All rights reserved MEC/23KM/T-25/10000012

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ENNORE TERMINAL PROJECT

Steelwork coming in direct contact with sheets shall be treated with two coats of zinc based primer and one coat of finish paint as topping coat. 27.3 27.3.1 Fixing of sheets All fixing of the roof and side sheeting to purlins/walling shall be by means of self drilling tapping screws. All screws/bolts shall pass through the crown of the corrugations for roof sheets and through trough corrugations for side sheets. Colour Coated sheets are to be provided with NPDM/neoprene washers. Fixing of the sheets with the purlins shall be as per the specification of the respective suppliers. Laps All normal roofing shall be provided not less than 150 mm for end & side laps for roof slopes between 15 to 18 . For roof slopes below 15 end laps shall be increased by at least 50mm for every 2 decrease in slope from 15 . All side/gable end sheets shall be provided not less than 150mm side lap and 100 mm end lap. Overhang of sheets on the roof and side cladding shall not exceed 300 mm. Erection Erection is to be carried out with the lay of the side laps such that under the prevailing wind, rain is not driven into the lap. The sheets shall be laid so that side laps in any two consecutive rows are staggered. Broken or otherwise damaged sheeting shall not be erected. Cutting, framing and trimming of all openings required shall be carried out at site. Grated Walkways/Grilled Flooring: Unless otherwise stated all grill flooring shall be designed for in addition to its self weight, for a superimposed load of 500 kg/m2 or the alternative minimum load specified in IS: 875 or the incidental load, due to erection, operation or maintenance
SECTION 9 (PART A) 1 Page 33 of 58 2010 MECON LIMITED. All rights reserved

27.3.2

27.3.3 27.3.4.

27.3.5

27.3.6 27.4 27.4.1

27.4.2 27.4.3 27.5. 27.5.1

Tenderers Signature with seal: Date:

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ENNORE TERMINAL PROJECT

or as specified in the drawing whichever is more critical. The maximum deflection due to dead load and live load should not be more than 1/200 span. 27.5.2 27.5.3. Material used for fabrication shall conform to IS: 2062-2006. Grill flooring shall be fabricated from flats of size 25x6 for main bars & 25x3 for secondary bent rib plates. Located of main bars at a spacing of not more than 40 mm and shall be provided with suitable transverse bent rib members to provide rigidity. Fabrication shall make provision to connect the flooring panels by bolts or by bolts and clips or welding to supporting members as per drawings. Provision shall also be made to interconnect the adjacent panels by bolts or by bolts and clips to prevent movement of floor panels. Top surface of all bars/members shall be flush giving a neat appearance. Welding of different members shall be by electroforge, electric resistance or similar type of welding so that there are no crude weld deposits or lumps. If permitted, grated walkways may be fabricated by manual arc welding. However, the welding shall be finished smoothly by proper grinding/filing. The fabricated floor panels shall be cleaned of all rust, dust, grease, oil, mill scale, weld flux etc., by blast cleaning to Swedish standard Sa 2 and made ready for painting. Painting shall be by cold dip process. First dip shall be in anti-saline metallic primer. After the primer paint has completely dried, the grill flooring shall be dipped for the second time in heavy duty anti-corrosive and wear resistant bituminous black paint. Minimum DFT of antisaline primer shall be 25 microns and minimum DFT of finishing paint shall be 75 microns. Sa 2 For cold dip painting a thinner recommended by the manufacturer in suitable quantities shall be added. During cold dip painting care shall be taken to guard against sagging or flow-down of paint. The gratings when erected around openings, shall have circular bands. Sample grating shall be got approved before taking up full scale manufacture.

27.5.4

27.5.5

27.5.6

27.5.7 27.5.8

Tenderers Signature with seal: Date:

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ENNORE TERMINAL PROJECT

SECTION - 4
28.0 28.1

SALIENT POINTS

QUOTATION The bidder should ascertain himself, by a visit to the site if necessary, the actual site conditions, local factors etc. The contractor shall bear full responsibility for deductions and conclusions as to the nature and conditions under which the work is to be executed, including effect of climate, rainfall etc. Failure to do so will not absolve the contractor of his responsibilities about the proper execution of the job. No claims for extra payments due to any special site conditions and ignorance of site conditions will be considered after acceptance of his quotation. The contractor shall indicate his price as per Schedule of Quantities, The cost of bolts (permanent and erection), washers, electrodes, putty, gases, cost of straightening the raw materials (hot bending not permitted), cutting of flats from plates and providing splices, paints, tool, plants, etc. as required for the work shall be deemed to be included in the quoted price. All handling and transport charges of raw materials and fabricated structures, including double handling if required, for completion of the work in accordance with time schedule are deemed to be included in the quoted price. Cost of NDT of welds as per specification shall be borne by the Contractor. For the welds found defective, the cost of retest shall be borne by the contractor in addition to the cost of rectification or replacement of the defective part. PROGRAMME A monthly time bar chart for various activities like procurement of steel, preparation and approval of fabrication drawings, fabrication, dispatch to site, erection and alignment, sheeting an painting etc. giving starting and completion dates of all activities, shall be submitted alongwith the bid without which the bid may not be considered for evaluation. The contractor shall also furnish his overall mobilization plan of construction equipment, their capacity etc. for prior approval of purchaser.

28.2 28.3

28.4

28.5

29.0 29.1

29.2

Tenderers Signature with seal: Date:

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ENNORE TERMINAL PROJECT

29.3

All programmes on procurement of raw steel and other materials, preparation of drawings, fabrication and despatch shall match with the sequence of erection of different structural components and different building/units, of the project as per planning. The purchaser may change or alter the detailed working programme for the sequence of work and for the fabrication of components of structures, within the frame work of the agreed schedule, which will be binding on the Contractor. If due to design or other stipulations in the bid or requirements at site, a particular sequence of overall construction has to be followed due to which certain interruptions to any one or more items of work are inherent, no claims for such interruption will be admissible. DRAWINGS The Contractor will be supplied with 2 (Two).copies of design drawings by the Purchaser. Based on the design drawings, the Contractor shall prepare general arrangement/marking drawings, fabrication drawings, erection drawings, bill of materials, shipping documents and nut and bolt lists. Bill of materials shall form part of fabrication drawings and shall be included in the body of the drawing or prepared separately. 6 (Six) copies of drawings and documents shall be submitted to the Purchaser for their scrutiny and approval. 2(Two) sets of the Fabrication drawings will be returned to the Contractor with a stamp signifying "Approved", "Approved as noted" or "Not Approved" on the drawing. After the final approval by the Purchaser the Contractor shall furnish to the Purchaser within two weeks 10 (ten) copies of the approved Fabrication drawings, and erection drawings. Despite approval of purchaser, Contractor shall not be relieved of his responsibilities for the accuracy of the detailed dimensions shown thereon and the safety of all structural connections as per forces indicated in the design drawings. Soon after the fabrication of steel work pertaining to a particular drawing is completed, immediate steps shall be taken by Contractor to incorporate in the approved fabrication drawings, all the authorised corrections, additions and alterations made during the course of fabrications and 2 (two) sets of the same shall be submitted to purchaser for his record.

29.4

29.5

30.0 30.1

30.2

30.3

30.4

Tenderers Signature with seal: Date:

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ENNORE TERMINAL PROJECT

30.5

Notes on specifications shown on design drawings shall be considered as superseding or overriding the specifications given elsewhere, with which they conflict. On all drawings, dimensions shown in figures shall be acted upon. After completion of erection, modification etc. the final as built drawings shall be submitted in 10 sets along with reproducible and CD to the consultant for further distribution and record. Supply and distribution of fabrication drawings and other documents like bolt list, etc. for the Contractor's own use or for the use of his Sub- contractors shall be the responsibility of the Contractor. The fabrication work shall be taken up only after the drawing status Approve as noted / Approved. MATERIAL The Contractor shall arrange and procure all steel sections, plates, MS Gratings, PVC pipes, Colour coated sheets, glazings, flashings, fixtures and fittings required for sheeting and glazing, aluminium or MS astragals and frames for glazing, clips, all the consumables like bolts, turned and fitted bolts, nuts including spares and service bolts, washers of different types, electrodes, gas, shims, packs, paints, etc. for completing the work satisfactorily and the cost of the same shall be deemed to have been covered in his quoted price. Where any raw materials required for the execution of the contract is procured with the assistance of the Purchaser or permit /license /quota certificate or release order issued by or on behalf of or under authority of Purchaser or by any officer empowered on their behalf by law, or where advance payments are made to the Contractor to enable him to purchase such raw material for execution of work, the Contractor:i) ii) Shall hold such materials as trustee for the Purchaser. Shall use such materials economically and solely for the purpose of the contract. Shall not dispose of the same without prior permission in writing from the Purchaser. Shall maintain and produce due documents indicating stock position / consumption of such materials from time to time, as required by purchaser.
SECTION 9 (PART A) 1 Page 37 of 58 2010 MECON LIMITED. All rights reserved MEC/23KM/T-25/10000012

30.6

30.7

30.8

31.0 31.1

31.2

iii)

iv)

Tenderers Signature with seal: Date:

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ENNORE TERMINAL PROJECT

31.3

The Owner may plan to procure and supply from the producers/stockyards major items of structural steel such as RS Joists, channels, angles, plates, chequered plates, tubes, Grating etc., required for the work. In that case these will be supplied to the Contractor in the indented lengths or standard lengths available, as received from the suppliers. CONTRACTOR'S RESPONSIBILITY The Contractor shall at his own cost properly store all materials brought by him to the work site/ Fabrication shop to prevent damage due to rain, wind, direct exposure to sun etc. and also from theft pilferage etc. EQUIPMENT All construction and equipment once brought by the Contractor within the Project Area, are not to be removed from there without the written authority from the purchaser. DESPATCH OF FABRICATED MATERIALS The Contractor is solely responsible for any loss or damage during transit to any of the fabricated members, and as such proper precautions shall be taken by him to guard against such mishaps. SETTING OUT The Contractor shall be responsible for checking the alignment and levels of foundations, correctness of foundation, centres of anchor bolts etc. well in advance of starting erection work and shall be responsible for any consequence for non-compliance thereof. Discrepancies, if any, shall immediately be brought to the notice of the Purchaser / Consultant. Any mistake subsequently found in alignment and levels of the structural steelwork due to non-verification of foundation before erection shall be corrected by the Contractor at his own expense. One set of reference axes and one bench mark level will be furnished to the Contractor. These shall be used for setting out of structures. Maintenance of such benchmark level shall be the responsibility of the Contractor. The Contractor at his own expenses shall provide measuring instruments for setting out, leveling and aligning steelwork.
SECTION 9 (PART A) 1 Page 38 of 58 2010 MECON LIMITED. All rights reserved MEC/23KM/T-25/10000012

32.0 32.1

33.0 33.1

34.0 34.1

35.0 35.1

35.2

35.3

Tenderers Signature with seal: Date:

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ENNORE TERMINAL PROJECT

36.0 36.1

STAGING Any staging necessary for the pre-assembly work of structures shall be provided by the Contractor at his own expense. RULES & REGULATIONS OF SAFETY, ELECTRICITY BOARDS, FACTORY ETC. The Contractor shall at all times comply with all relevant factory acts, electricity rules, safety regulations etc. as per statutory regulations of Central / State Government. DEVIATIONS Should the Contractor wish to deviate from any specification or details shown on the purchaser's approved drawings and / or Technical Specifications, he shall obtain the purchaser's written authority before proceeding with the deviations. BASIS OF PAYMENT The tenderer shall give the break-up prices as required in the Schedule of Items. As the quantities mentioned are estimated quantities, payment will be made on the actuals as per the agreed rates. MEASUREMENTS Structural Steel Structural steelwork will be measured by the metric tonne and as per IS: 1200 (part-8) - 1993 and IS: 1200-(part-9)-1973 subject to provisions outlined below: a) The calculation of quantities shall be based on unit on weights for structural sections as given in IS: 808-1989. In the case of mild steel/SAIL-MA Steel plates, the calculated weights shall be based on 78.5 kg per square metre per centimetre thick plate. The payments will be made on the basis of weights of members given in the approved fabrication drawings. However, any changes on the above weights during fabrication erection, payment shall be based on sketches Approved by the purchaser. In the event the I.S. does not specify any mode of measurement for a particular item of work, the same shall be measured as per any other relevant international standard or as directed by the Purchaser.
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37.0 37.1

38.0 38.1

39.0 39.1

40.0 40.1

b)

Tenderers Signature with seal: Date:

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ENNORE TERMINAL PROJECT

c)

The weight of all plates and sections shall be calculated from the approved drawing using the minimum overall square or rectangular dimensions and theoretical weight, no deduction being made for skew cuts, holes etc. In the case of plates, other than gussets, the actual dimensions shown on approved drawings will apply unless approved otherwise by the purchaser based on cutting diagram of mother plates. The weight of all welding runs, bolt, stanchion base packing, cuttings to waste and rolling margins, and coatings of paint, will be excluded from the measured weight and shall be deemed to have been allowed for in the rates for structural steelworks quoted by the Contractor. Temporary works and all other materials not included in the permanent works shall be excluded from any measurement for payment.

d)

e)

40.2 40.2.1

Colour Coated Sheets Colour coated sheets for roofing, louvres of big size and side cladding shall be measured by the square metre of net laid area, as specified and shown on the drawings. No allowance shall be made for wastage, cut-outs, over laps etc. in the measurement. The unit rate in 40.3.1 shall include all fasteners, flashings and fitting such as ridges, corners, aprons and other accessories. No deduction will be made for openings for area less than a single sheet. Also no extra payment will be made for making openings. PRELIMINARY ACCEPTANCE After completing the erection of a unit or portion thereof, the Contractor shall give a notice in writing stating that the job is complete in all respects and ready for preliminary acceptance .The job shall be jointly inspected visually by representatives of Contractor and Purchaser. All observed defects and omissions as per drawing and specification shall be noted down. If the defects are not major in the opinion of the purchaser/Purchaser's representative, the Contractor will be issued a preliminary acceptance certificate mentioning the defects, deficiencies and omissions which shall be made good by the Contractor within a period of 2 weeks or at the earliest.

40.2.2 40.2.3

40.2.4.

40.3 40.3.1

Tenderers Signature with seal: Date:

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ENNORE TERMINAL PROJECT

40.4 40.4.1

FINAL ACCEPTANCE Before commencement of inspection for final acceptance of the building or unit, the Contractor shall make available six complete sets of all drawings, representing "AS BUILT" drawing, (i.e. all additions and alterations done during fabrication and erection shall be incorporated in the drgs, Refer clause 30.4 & 30.6 The Contractor shall make good all defects deficiencies and omissions noted down during preliminary acceptance (Refer clause 40.3.1) and shall inform in advance the Purchaser/ his representative for conducting inspection for final acceptance. Final acceptance certificate will be issued by the Purchaser / his representative only after all defects / deficiencies / omissions noted under Preliminary Acceptance have been rectified.

40.4.2

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SECTION- 5
41.0 41.1

PAINTING OF STEEL STRUCTURES

SURFACE PREPARATION FOR PAINTING General The steel surface which is to be prepared shall be cleaned of dirt and grease and the heavier layers of rust shall be removed by grinding prior to Actual surface preparation to a specified grade. Surface preparation to be followed prior to painting shall be based on the requirement of a particular painting system as per clause 43.0. Some of the specifications for surface preparation is given below for reference but the particular specification for surface preparation shall be followed as per schedule of works given to the contractor for price bid.

41.2 41.2.1

Mechanical Cleaning Manual/power tool cleaning. Manual/power tool cleaning shall be done as per grade St-2 or St-3,of Swedish Standard Institution SIS 055900. i) Grade St-2: Thorough scraping and wire brushing, machine brushing, grinding etc. This grade of preparation shall remove loose mill scale, rust and foreign matter. Finally the surface is to be cleaned with a vacuum cleaner or with clean compressed air or with clean brush. After preparation, the surface should have a faint metallic sheen. The appearance shall correspond to the prints designated St-2. Grade St-3: very thorough scraping and wire brushing, machine brushing, grinding etc. The surface preparation is same as for grade St-2 but to be done much more thoroughly. After preparing the surface, it should have a pronounced metallic sheen and correspond to the prints designated St-3.

ii)

41.2.2

Blast Cleaning

41.2.2.1 Blast cleaning shall be done by shot blasting as per following grades according to Swedish Standard SIS 055900.
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(i) Grade Sa-2.This involves light blast cleaning. Almost all mill scale, rust and foreign matter shall be removed. Finally the surface is cleaned with a vacuum cleaner, clean dry compressed air or a clean brush. The surface shall look greyish in colour and correspond in appearance to the prints designated as Sa-2. (ii) Grade Sa 2 : This involves very thorough blast cleaning. Mill scale, rust and foreign matter shall be removed to the extent that the only traces remain in the form of slight stains. Finally the surface is cleaned with a vacuum cleaner, clean dry compressed air or a clean brush. It shall then correspond in appearance to the prints designated as Sa 2.

(iii) Grade Sa-3: This involves blast cleaning to pure metal surface. Mill scale, rust and foreign matter shall be removed completely. Finally the surface is cleaned with a vacuum cleaner, clean dry compressed air or a clean brush. Then the surface shall have a uniform metallic colour and correspond in appearance to the print designated as Sa-3 41.2.2.2 For details of blast cleaning and shot blasting, refer ANNEXURE-F. 41.2.3 Flame cleaning Flame cleaning shall also be carried out with the help of a special oxy-acetylene torch and the loosened mill scale shall be removed with a wire brush. This process is not recommended for cleaning steel sheet or plates less than 6 mm in thickness as it may lead to buckling .The number of flame passes on such surface shall be limited to three. The primer coat of paint shall be applied when the surface is still warm, after removing the scales with brushing and wiping. 41.3 Surface preparation shall be done as shown in the schedule of works given to the contractor for price bid. PAINTS AND PAINTING For use of specific painting system, the paint manufacturer's specification shall prevail. General compatibility between primer and finishing paints shall be established through the paint manufacturer supplying the paints.

42.0 42.1 42.2

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42.3

Before buying the paint in bulk, it is recommended to obtain sample of paint and establish "Control Area of Painting". On control area surface preparation and painting shall be carried out in the presence of manufacturer of paint. In order to ensure that the supplied paint meets the stipulation in design drawing/ specification, if required, samples of paint shall be tested in laboratories to establish quality of paint with respect to (i) Viscosity (ii) adhesion/ bond of paint in steel surfaces (iii) adhesion/simulated salt spray test (iv) chemical analysis (percentage of solids by weight) (v) normal wear resistance as encountered during handling & erection (vi) resistance against exposure to acid fumes etc. Whole quantity of paint for a particular system of paint shall be obtained from the same manufacturer. Thinners, wherever used, shall be as per recommendation of the paint manufacturer. Areas which become inaccessible after assembly of structures shall be painted before assembly, after cleaning the surfaces as specified. Wherever shop primer painting is scratched, abraded or damaged, the surfaces shall be thoroughly cleaned using emery paper and power driven wire brush wherever warranted, and touched up with corresponding primer. Touching up paint shall be matched and blended to eliminate conspicuous marks. If more than 50% of the painted surface of an item requires repair, the entire item shall be mechanically cleaned and new primer coats shall be applied followed by finishing coats as per painting specification. All field welded areas on shop painted item shall be mechanically cleaned (including the weld area proper, adjacent areas contaminated by weld spatter or fumes and areas where existing primer. intermediate / finishing paint is burnt). Subsequently, new primer and finishing coats of paint shall be applied as per painting specification.

42.4

42.5

42.6 42.7

42.8

42.9

42.10

Application of paint shall be by spraying or brushing as per IS:487-1997 and in uniform layers of 50% overlapping strokes. Painting shall not be done when the temperature is less than 5C or relative humidity more than 85%, unless manufacturer's recommendations permit. Also painting shall not be done in frosty or foggy weather. During application, paint agitation must be provided wherever such agitation is recommended by the manufacturer.
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42.11

Paint shall be applied at manufacturer's recommended rates. The number of coats shall be such that the minimum dry film thickness (DFT) specified is achieved. The dry film thickness of painted surfaces shall be checked with ELCOMETER or measuring gauges to ensure application of specified DFT. All structures shall receive appropriate number of primer and finishing coats in order to achieve overall DFT as per design drawings/ specifications. First coat of primer paint shall be applied not later than 2-3 hours after preparation of surface, unless specified otherwise. The finishing paint as specified shall be of approved colour and quality. The under coat shall have different tint to distinguish the same from the finishing coat. Edges, corners, crevices, depressions, joints and welds shall receive special attention to ensure that they receive painting coats of the required thickness. Machine-finished surface shall be coated with white lead and tallow before shipment or before being put into the open air. Parts of surfaces embedded in concrete shall be thoroughly cleaned of grease, rust, mill scale etc. and shall be given a protective coat of portland cement slurry immediately after fabrication. No paint shall be applied on this part. Zinc-rich primer paints, which have been exposed several months before finishing coat is applied, shall be washed down thoroughly to remove soluble zinc salt deposits. In similar circumstances, the surfaces of paint based on epoxy resin should be abraded or lightly blast cleaned to ensure adhesion of next coat. Surfaces which cannot be painted but require protection shall be given a coat of rust inhibitive grease according to IS: 958-2000 or equivalent international standard. PAINTING SYSTEM The recommended painting system for general service requirement of steel structures covering surface preparation, application of primer coats, intermediate coats and final coats to develop the required minimum dry film thickness on steel surface is indicated in ANNEXURE-E.

42.12

42.13

42.14

42.15

42.16

42.17

42.18

43.0

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ANNEXURE-A Permissible deviations in pitch and gauge of holes for bolts of normal accuracy (high strength bolts included) Description Hole diameter (mm) 2 Upto 17.0 Above 17.0 Permissible Deviations in Spacing (mm) 3 +1 +1.5 Permissible deviations in each group of holes Carbon Steel 1 a) Deviation in the hole diameter b) Ovality (difference between the biggest and the smallest diameter) c) Curves, exceeding 1mm and cracks on the hole edges d) (i) Non-coincidence of holes in separate details of the assembled unit, upto 1mm (ii) Above 1 mm upto 1.5 mm e) Slope of axis 4 No limits Low Alloyed Steel 5

Upto 17.0; Above 17.0;

+1 +1.5

No limits

Not Permissible

Upto 50%

Upto 50%

_ _

_ Upto 30% of the thickness of unit

Upto 10% No limits

Upto 10%

No limits

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ANNEXURE B TOLERANCE OF ASSEMBLED COMPONENTS OF STRUCTURES Description of Deviation () in mm for the Elements of Structures Components of Length in Metres

Structures 1 I. i) Deviations from the dimensions assembled. Length & width of the Details Cut : a) Manual gas Cutting as per marking b) With shears or with a saw as per marking c) With shears or with a saw with a stop d) Machine Gas Cutting ii) Length and width of planed ends processed on Edge Planing Machine II i) Distance between the Centres of the End holes. a) Drilled according to marking b) Drilled according to a gauge with bushing ii)Distance between the centres of adjacent holes a) Drilled according to marking or to a gauge b) Drilled according to a gauge with bushings
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Up to 1 2

1 to 5 3

5 to 10 4

10 to 15 5

15 to 20 6

20 to 25 7

Over 25 8

3 2 1.5 2 1

3.5 2.5 2 2.5 1.5

4 3 2.5 3 2

4.5 3.5 3 3.5 2.5

5 4 3.5 4 3

2 1

2.5 1.5

3 2

3.5 2.5

4 3

1.5 0.5

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III. Deviation in the dimensions of despatch elements after completion of fabrication, Assembled in positioners or in other Devices with clamps in fixed positioners and also a) According to guide blocks with pins. b) Assembled with bolts c) Size (length & width) between Milled surface (for all cases of assembly) d) The same made in separate details during machining & fixed during the assembling work with clamps e) The same drilled according to positioners in finished structures

2 3 1

3 5 1.5

5 8 2

7 11 2.5

8 12 3

9 14 3.5

10 15 4

10

1.5

2.5

3.5

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ANNEXURE C

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ANNEXURE D TOLERANCES IN ERECTED STEEL STRUCTURES Sl No. A. 1. Description COLUMNS Deviation of column axes at foundation top level with respect to true axes. i) In Longitudinal direction 5 5 5 Tolerance (mm)

ii) In Lateral direction 2. Deviation in the level of bearing surface of columns at foundation top with respect to true level Out of plumbness (vert.) of column axis from true vertical axis and measured at column top : a) For columns without any special requirements : i) Upto and including 30m ii) Over 30 m height b) For column with special requirements like cranes or such similar requirements : i) Upto and including 30m ii) Over 30 m height Deviation in straightness in longitudinal & transverse planes of columns, at any point along the height Difference in the erected position of adjacent pairs of columns along length or across width of building, prior to connecting trusses / beams, with respect to true distance. Deviation in any bearing or seating level with respect to true level.
SECTION 9 (PART A) 1 Page 51 of 58 2010 MECON LIMITED. All rights reserved

3.

H/1000 or 25mm height whichever is less H/1200 or 35mm maximum

H/1000 or 20mm height whichever is less H/1500 or 25mm maximum H/1000 or 10mmwhichever is less

4.

5.

6.

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7.

Difference in bearing levels of a member on adjacent pair of columns both across and along the building, from the true difference.

NOTE: i) Tolerance specified under 3(a) and 3(b) should be read in conjunction with 4 and 5. ii) "H" above is the column height in mm.

B. 1.

2.

3. 4. 5.

TRUSSES Shift, at the centre of top chord member of truss with respect to the centre of span or vertical plane passing through the centre of bottom chord. Lateral shift of top chord at the centre of truss span from the vertical plane passing through the centre of supports of the truss. Lateral shift in location of truss from its true vertical position.

1/250 of height span in mm or 15 mm whichever is less

1/1500 of span of truss in mm or 10 mm whichever is less

10

Lateral shift in location of purlins from 5 true position. Deviation in difference of bearing levels L/1200 or 20 mm whichever is less of trusses or beam from the true (L =span) difference.

NOTES: 1. The tolerances specified do not apply to steel structures where deviations from true positions are intimately linked with or directly influence the technological process. In such cases, the tolerances on erected steel structures shall be as per recommendations of process technologists / equipment suppliers. 2. The observed or calculated values of deviations of steel structures from their true positions shall be rounded off in accordance with IS:2-1960 for comparison with permissible tolerances specified in this table. The number of significant places retained in the rounded-off value should be same as that specified in this table.
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ANNEXURE - E PAINTING SYSTEM

Surface preparation: Sa 2 according to Swedish Standard SIS 055900

1 2 3 4

First Coat (Primer) Second Coat (Intermediate) Third Coat (Finishing) Fourth Coat (Finishing) Total Thickness

: : : : :

Epoxy Zinc phosphate 50 microns DFT Epoxy polymide micaceous iron oxide 75 microns DFT High Build Epoxy polymer 90 microns DFT Epoxy polyurethene 35 microns DFT 250 Microns

Painting system conforming to IS: 2932-2003

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ANNEXURE-F SPECIFICATION FOR SURFACE PREPARATION WITH BLAST CLEANING/SHOT BLASTING 1.0 1.1 General As adhesion of the paint to surface depends on the degree of cleanliness of the metal surface, surface preparation shall be done by Air blast cleaning to achieve maximum durability. Mill scale, rust, rust scale and foreign matter shall be removed fully to ensure that a clean and dry surface is obtained. The minimum acceptable standard of prepared surface shall be SSPC SP-10 or Sa 2 as per Swedish Standard SIS-055900-1967. Remove all other contaminants, oil, grease etc. by use of an aromatic solvent prior to surface cleaning. 1.3 Blast cleaning shall not be performed where dust can contaminate surfaces undergoing such cleaning or during humid weather conditions having humidity exceeding 85%. With in 4 hours of surface preparation, the first coat of primer must be applied on dry surface. However, at times of unfavorable weather conditions, the Engineer-in-Charge shall have the liberty to control the time period, at his sole discretion and/or to insist on re-cleaning, as may be required, before primer application is taken up. In general, during unfavorable weather conditions, blasting and painting shall be avoided as far as practicable. Procedure of Surface Preparation Air Blast Cleaning The blast cleaning of the surfaces shall be done using abrasive media like Al203 particles, copper slag, or other standard media at a pressure of 7 kg/cm2 at appropriate distance and angle depending on nozzle size maintaining constant velocity and pressure. Compressed air shall be free from moisture and oil. The blasting nozzles should be venturi style with tungsten carbide or boron carbide as the materials for liners. Nozzles orifice may vary from 3/16" to ".
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1.2

1.4

2.0 2.1 2.1.1

2.1.2

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2.1.3

On completion of blasting operation, the blasted surface shall be clean and free from any scale or rust and must show a gray white metallic lusture. Primer shall be applied within 4 hours of surface preparation. Blast cleaning shall not be done outdoors in bad weather without adequate protection or when there is dew on the metal which is to be cleaned. Surface profile shall be uniform to provide good key to the paint adhesion (i.e. 35 to 50 micron). If possible vacuum collector, shall be installed for collecting the abrasives and recycling.

2.1.4

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ANNEXURE - G

MATERIAL OF CONSTRUCTION (AS APPLICABLE)


1. Unless otherwise specified in the drawing: a) All rolled sections and plates shall conform to Grade-A as per IS: 2062-2006. b) Plated structures subjected to dynamic loading shall conform to Grade-B as per IS: 2062-2006. c) High strength micro-alloyed steel shall conform to SAIL-MA 350 HYA/HYB (SAIL product). 2. 3. 4. Steel sheets shall conform to IS: 1079-1994. Steel tubes for structural purposes shall conform to IS: 1161-1998 (Grade YST-240). a) Colour Coated Sheets (Refer Section-3) b) Translucent Sheets (FRP) of thickness 2mm at specific locations to match with the colour coated troughed sheet and shall conform to IS:12866-1989(FRP) 5. 6. 7. 8. Gutters and down comers shall be of copper bearing steel conforming to IS: 2062-2006. Crane rails shall conform to IS: 3443-1980. Glazing shall be 6 mm thick rough cast wired glass as per IS: 3548-1988.

All black hexagonal bolts, nuts and locknuts shall conform to IS: 1363-2002 and IS: 1364-2002 (for precision and semi- precision hexagonal bolts). Washers shall conform to IS: 2016-1967. All HSFG bolts shall conform to IS: 3757-1985. Covered electrodes for arc welding shall conform to IS: 814- 2004. Coding of electrodes shall be as follows: a) ER 421 'C' x for mild steel of Grade A and Grade-B as per IS: 2062-2006.
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9. 10

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b) EB 542 'C' x H3X for i) Mild Steel of Grade B as per IS: 2062-2006 for dynamically loaded structures (arising out of crane, vibratory screen, equipment etc.) ii) For SAIL-MA micro alloyed steel 350 HYA/HYB. iii) When combined thickness (CT) for steel conforming to IS: 2062-2006 exceeds 40mm as per Fig.1 "C" is the value of current as recommended by the electrode manufacturer.

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ANNEXURE-H

LIST OF RECOMMENDED MAKES/MANUFACTURERS


General: The makes and manufactures shall be preferably from the following list. In case some of the items not available in the market or some of the particular products are not producing by the following manufacturer or incase of change in trade name etc. equivalent makes or redesignated product shall be used conforming to the specific IS codes with the prior approval of purchaser/consultant. In case of some items not covered in this list like fasteners, fixtures etc. may be procured form the market conforming to IS codes with test certificates and prior approval from the purchaser/consultant.

Sl.No. 1 2 3

Item Structural Steel Electrodes Paint

Manufacturer SAIL,RINL,TISCO,JINDAL,ESSAR ADOR (Advani orlikon), D & H, ESAB BERGER, SHALIMAR, AKZO-NOBEL, SIGMA Coating, ASIAN. Japan metal building system, Interarch building products, Tata Blue scope, Lloyd Insulation (I) Ltd. Colour Roof India, CRIL colour roof India, G.K.Roofing India (P) Ltd. ERCON Composites SANGIR Plastics Associated Engineering Corporation SAIL, JINDAL

Colour coated sheet

5 6

FRP Grating CGI Sheet

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MEC/23KM/T-25/10000012