04 Vol-III-B-Technical Specification For Civil Works

TECHNICAL SPECIFICATION CIVIL WORKS
Volume-IIIB: 24x7 water supply project of Gandhinagar

Technical Specification for Civil Works Smart City
1 R.C.C. GSR
Preparing structural design of RCC Under Ground / Partially under ground / above high
ground level Reservoir of required capacity as per relevant I.S. standards and constructing
the same, including excavation in all types of soil strata (including rock) including shoring
strutting if required, for loose soil / to protect from collapse, casting 100 mm thick P.C.C.
levelling course in M-15, Refilling the pit with proper soil and disposing of the surplus stuff at
all lead. Including cement plaster in CM 1:2 with approved water proofing compound to all
over inside container (i.e. walls, base, top slab/dome bottom etc. all). Including all types of
labour and material charges of lowering, laying, erecting / hosting and jointing of pipe
assembly to inlet, outlet overflow, washout and bye pass arrangement as per hydraulic
design. Providing and fixing accessories, CI Manhole frame and cover, water level indicator,
adequate cowl type ventilators or lantern type ventilator with stainless steel jail. RCC
chambers for valves. Providing and applying three coats of cement paint / snowcem to the
out side face of structure. It also includes satisfactory water tightness test as per relevant I.S.
code and painting name of scheme and capacity on the tank as per direction of engineer in
charge.
List of Indian Standards for Design of GSR / SUMP:-
The structural design of GSR shall be in accordance with provisions relevant I.S standards
(1) I.S. 3370 part I & II 2009 or Its latest revision
(1.1) I.S. 3370 part III & IV 1965 or Its latest revision
(2) I.S. 456 – 2000 or Its latest revision.
(3) I.S. 1893 – 2000 – 1984 or Its latest revision.
(4) I.S. 875, Part – 1 to 3, 1987 or Its latest revision.
General Specifications:-
(1) Water depth in container shall be adopted as per data of tender. Capacity shall be
calculated excluding free board of the reservoir. If water depth is not specified, the suitable
water depth / acceptable to field engineer in accordance with hydraulic requirement shall be
adopted for capacity.
(2) Shape of container (in plan) specified by in data shall be adopted in absence circular
shape shall be adopted.
(3) Size shall be fixed as per availability of space (land area) at site / acceptable engineer in
charge.
(4) Effect of overlapping of pressure bulbs on soil due near by structure and proposed sump
should be considered.
(5) Care shall be taken that no damage should occur to nearby existing structure.
Compensation shall be paid for the same by agency.
(6) The minimum concrete grade for RCC shall be M-30.
(7) HYSD Fe 415 / 500 grade reinforcing bars confirming to I.S. 1786 / 1139 shall be
considered in design. CRS / TMT bars shall be provided. In saline atmosphere corrosion
resistance stainless steel / HCR rebar shall be provided. Any other steel can be used with
approval of C.E./ in situation of non availability in market without extra cost.
(8) Minimum size (or thickness) of various components shall be provided as per tender
criteria / specifications in absence as per I.S./ Std. practice of G.W.S.S.B. Minimum
dimensions specified for various components in tender data / specifications shall be provided
without fail.
GWSSB 1
(9) The safe bearing capacity (SBC) shall be referred from SBC test report. In absence of
report it shall be referred from data sheet. If poor soil is found / water table is met with during
excavation SBC shall be scientifically ascertained and design shall be revise. No extra shall
be paid for increase in quantity.
(10) DI pipes and special shall only be used if type is not specified in tender.
(11) The rate shall include cost of dewatering during excavation making all arrangement
when water table meets within depth.
(12) The structure shall be designed properly to resist uplift due to ground water table
specified in data or actual ground water table meets with during excavation. If GWT / Uplift is
mentioned in tender and during excavation it dose not meet 7.5% rate shall be reduced.
(13) SS pipes railing shall be provided over sump perifery when sump height is ≥ 1.5 meter
above ground level.
(14.a) RCC staircase/RCC Steps should be provided from GL to sump top slab based on the
height of the GSR above/below the ground.
(14.b) RCC Staircase with SS railing to be provided inside reservoir container. BB Masonry
staircabin to be provided to cover the same with MS safety door having locking arrangement.
(15) Appearance of structure should be aesthetically good looking acceptable to authority.
(16) Any change in size, shape, depth below GL, height above GL, water depth, F.B., size of
member etc can be permitted in exceptional case due to site condition or hydraulic design
requirement by C.E. No extra shall be paid for change.
(17) Any change in data, dimensions, shape, water depth, reduction in size if permitted by
competent authority and if it reduces quantity then payment shall be reduced prorate.
(18) When capacity of GSR / Sump is > 20 lakh litres two or suitable compartments
acceptable to executive engineer shall be designed and provided.
(19) Agency shall engage qualified (at least graduate) consulting engineer for designing the
structure and he / she shall visit the site for guidance of work.
(20) 75% part rate shall be payable for concrete, reinforcement and plastering items of
container until satisfactory hydraulic testing for water tightness is performed as per tender
condition. Till the work shall be treated as incomplete.
Above conditions / general specifications Sr. No. 1 to 20 are part and parcel of tender
(contact) and prevail over other provisions in tender.
Gunniting exterior surface for Civil Structures only
Gunniting the surface in CM 1:2 having thickness of 40 mm to 50 mm (Ave.) for beam,

braces, column and container slab incl. chiselling and scraping loose concrete cleaning the
surface with water and air under pressure and including providing and fixing in position steel
wires square mesh 75 mm x 75 mm as per IS:1966-1982 3.15 mm Wt/Sq.Mt. 1.64 Kg. with
spot welding wherever necessary with main reinforcement incl. tying binding with wire incl.
scaffolding centering staging all equipment and materials etc. complete incl. labour and
testing of the container.
Gunniting Internal Surface
Providing the gunniting to interior surface of cement / masonry / Water Tank of various
capacities as specified at various places with cement mortar (1:2) in thickness of 40 mm
including chiselling and scraping loose concrete and plaster incl. providing and fixing in
position 6 mm dia. mild steel bars reinforcement at 15 cm c/c both ways including fabricating
and cost of binding wires including centering , staging all equipments etc. complete
including scaffolding , carting of all type of material and equipments to site of work and giving
hydraulic testing up to satisfaction of engineer in – charge .
GWSSB 2
For top , bottom of ESR/ GSR/tank /cistern

With vertical walls ,columns, braces and shaft up to6 m height
Do- for columns ,braces and shaft staging above 6m height
Do- for RCC container (inside)
Pressure Grouting
Providing pressure grouting at 5.6 Kg/Sq.cm in required row/zigzag fashion as specified at

1.5 m interval as per site conditions to stop leakages from water retaining structures
including supply of cement and hardening chemical, bringing equipments like compressor
and all scaffolding works to get smooth finishing as directed by engineer in charge.
(1) To masonry structures
(2) Concrete/RCC structures
Drilling holes for grouting
Drilling 40 mm Dia. Holes in masonry/concrete structures with providing and fixing 500 mm
long GI Pipeline for pressure grouting including supply of material, machineries and labour
cost etc. complete.
Work includes Conducting site investigations(site survey & soil investigation) &Preparing
structural design of RCC Under Ground / Partially underground / above high ground level
Reservoir of required capacity as per relevant I.S , as per requirements of Tender technical
specifications & data sheet, obtaining approvals of designs, and constructing the same,
including excavation in all types of soil strata (including rock) including shoring strutting if
required, for loose soil / to protect from collapse due to nearby traffic load, casting 100 mm
thick P.C.C. leveling course in M-15, Refilling the pit with proper soil and disposing of the
surplus stuff within a lead of 50 meters. Including cement plaster in CM 1:3 with approved
water proofing compound to inside water touching surface to container. Including all types of
labour and material charges of lowering, laying, erecting / hosting and jointing of pipe
assembly to inlet, outlet overflow, washout and bye pass arrangement as per hydraulic
design.The designs shall be based on relevant Seismic Zone and actual site geotechnical
investigations and site condition by the Contractor.
Providing and fixing accessories like MS / GI Ladder, CI Manhole frame and cover, water
level indicator, adequate cowl type ventilators or lantern type ventilator with stainless steel
jail.
B.B. Masonry chambers for valves. Providing and applying three coats of cement paint /
snowcem to the outside face of structure. It also includes satisfactory water tightness test
as per relevant I.S. code and painting name of scheme and capacity on the tank as per
direction of engineer in charge.
List of Indian Standards for Design of GSR / SUMP:-

The structural design of GSR shall be in accordance with provisions relevant I.Ss.
(1) I.S. 3370, Part – 1 to 4, 1965 or latest revised.
GWSSB 3
(2) I.S. 456 – 2000 or latest revised.

(3) I.S. 1893 – 2000 – 1984 or latest revised.
(4) I.S. 875, Part – 1 to 3, 1987 or latest revised.
1. Water depth in container shall be adopted as per data of tender. If water depth is not
specified the suitable water depth / acceptable to field engineer in accordance with
hydraulic requirement shall be adopted for capacity.
2. Shape of container (in plan) specified by in data shall be adopted in absence circular
shape shall be adopted.
3. Size shall be fixed as per availability of space (land area) at site / acceptable
engineer in charge.
4. Effect of overlapping of pressure bulbs on soil due nearby structure and proposed
sump should be considered.
5. Care shall be taken that no damage should occur to nearby existing structure.
Compensation shall be paid for the same by agency.
6. The minimum concrete grade for RCC shall be M-30
7. HYSD Fe 415 / 500 grade reinforcing bars confirming to I.S. 1786 / 1139 shall be
considered in design. CRS / TMT bars shall be provided. In saline atmosphere
corrosion resistance stainless steel / HCR rebar shall be provided. Any other steel
can be used with approval of C.E./ in situation of non-availability in market without
extra cost.
8. Minimum size (or thickness) of various components shall be provided as per tender
criteria / specifications in absence as per I.S./ Std. practice of G.W.S.S.B. Minimum
dimensions specified for various components in tender data / specifications shall be
provided without fail.
9. The safe bearing capacity (SBC) shall be referred from SBC test report. In absence
of report it shall be referred from data sheet. If poor soil is found / water table is met
with during excavation SBC shall be scientifically ascertained and design shall be
revise. No extra shall be paid for increase in quantity.
10. CI/DI pipes and special shall only be used if type is not specified in tender.
11. The rate shall include cost of dewatering during excavation making all arrangement
when water table meets within depth.
12. The structure shall be designed properly to resist uplift due to ground water table
specified in data or actual ground water table meets with during excavation. No extra
shall be paid. If GWT / Uplift is mentioned in tender and during excavation it does not
meet 7.5% rate shall be reduced.
13. GI pipes railing shall be provided when sump is more than 2 meter above ground
level.
14. Appearance of structure should be aesthetically good looking acceptable to authority.
15. Any charge in size, shape, depth below GL, height above GL, water depth, F.B., size
of member etc can be permitted in exceptional case due to site condition or hydraulic
design requirement by C.E. No extra shall be paid for change.
16. Any charge in data, dimensions, shape, water depth, reduction in size if permitted by
competent authority and if it reduces quantity then payment shall be reduced prorate.
17. When capacity of GSR / Sump is > 20 lakh liters two or suitable compartments
acceptable to executive engineer shall be designed and provided.
GWSSB 4
18. Agency shall engage qualified (at least graduate) consulting engineer for designing
the structure and he / she shall visit the site for guidance of work.
1.1 ClearWater Sump
Clear water sump shall preferably be rectangular shape with compartments if capacity > 20
L Liters. A common inlet chamber with sluice gate shall be provided. All pipe work, gates,
valves etc. shall be provided to each isolated compartment. The sump shall be constructed
in RCC with concrete design mix of M30 grade and CRS/TMT steel reinforcement of grade
Fe 415/500/500 D. The sump shall be provided with a sump on one side of the sump facing
Clear Water Pumping Station. The sump shall be water tight. The responsibility of water
tightness, structural stability shall be of the contractor.
The clear water sump shall also be provided with the following arrangements
a) Inlet arrangement Common inlet chamber with separate inlet gate

arrangement for each compartment shall be
provided. The inlet gate size shall be as per
approved L section. The pipe shall be provided
with puddle pipe with provision for connecting
out let from future treatment plant.
b) Outlet As required
arrangements
c) Scour The sumps shall be provided with scour

arrangement arrangement to empty the tank at the lowest
point in the sumps and the arrangement shall be
taken to a suitable distance to let out the water
into a natural stream of valley or lowest point as
directed by Project Manager.
d) Overflow The sumps shall be provided with overflow

arrangement arrangement at MWL with a sufficient lead drain
to drain the water into a natural stream of valley
or lowest point as directed by Project Manager.
The overflow pipe will be as per the design
Requirement.
e) Free Board The sumps shall be designed with a minimum

free board of 0.3 m below soffit of beam..
The sump shall be covered with Dome / Flat RCC roof slab. Sufficient number of
ventilators made of anticorrosive material shall be provided. Sufficient Manhole openings
(as per GWSSB guidelines) are to be provided with MS / R C. stair case of minimum width
of 800mm with S.S. 304 grade handrail, to enter into the sump compartments. All
materials shall be anti-corrosive. The water contact surface including the freeboard area,
the ceiling, walls of the sumps and all steel components shall be provided with anti
corrosive protection and protection from chlorine effects. Access to sump roof shall also be
provided.
GWSSB 5
1.2 Criteria for preparation of designs:

Capacity of the tank shall be the volume of the water it can store between the designed full
supply level (F.S.L) and lowest supply level (L.S.L) i.e. the level of the lip of the outlet pipe.
Due allowance shall be made for 20 mm thick W.P plastering the tank from inside, while
calculating the capacity of the tank.
Freeboard is the vertical distance between F.S.L. and Sofit of covering slab or lowest point
of dome or beam supporting the cover. In any case the free board shall not be less than
300 mm from bottom of beam.
Dead storage shall be the storage capacity of water below L.S.L. depth of dead storage
shall be the vertical distance between the top outlet levels and wash out level. The washout
pipe level shall be at the lowest portion of the container.
Water depth in the tank shall be the vertical distance between L.S.L. and F.S.L. of tank.
Bearing capacity shall be determined by carrying out actual soil exploration and tests due
to conditions as mentioned in para 2.0 of IS 1992-1969. The same shall be carried out by a
Government laboratory or any other approved laboratory and allowable bearing capacity so
arrived shall be taken as the basis of design. The factor of safety adopted in case of actual
test shall be as per clause 6.1 (A) of IS 6403-1971.
IS: 1893 (Part-I and Part-II):2002, IS 875 Part-III 2002, IS 13920, IS 4326 and GSDMA
Guidelines shall be followed.
The contractor shall submit a note on design methodology and construction as prepared by
design engineer after the award of contract. The note should indicate general description
and salient features of the design covering following points.
1. Capacity
2. Shape & type.
3. S.B.C. adopted in the design i.e. S.B.C. of strata based on actual test report and type
of foundation proposed with proper justification.
4. Site plan showing location.
5. Line diagram showing dimensional and sectional elevation with important levels.
6. Plan showing piping arrangement.
7. Design parameters proposed to be adopted for detailed design.
1.3 Design Requirements:

Foundation for GSR
The foundation shall be designed for actual S.B.C. of strata confirmed by Soil Investigation
Report and recommendations provided in report as per I.S 6403 & I.S 1904. The total
depth shall not be less than 1.5 m for individual footing. Minimum thickness of 100 mm to
be considered for levelling concrete with M15 grade.
The free board shall be 300 mm below soffit of roof beam or lowest point of dome and shall
be included in the depth of water for design purpose.
GWSSB 6
Maximum actual water depth excluding free board shall not exceed 6.0 m.
The design shall be for Seismic Zone as per latest I.S 1893.
Contractor to carry out soil investigation of standing water table for design purpose during
monsoon season, retrieve data of last five years from EE and as per actual site condition
during execution and the maximum depth of water table should be consider for uplift check
design purpose.
Columns inside container for supporting roof beam/ slab may be provided as per design
requirement. However the size shall not be less than 300 mm dia. No square or rectangular
columns shall be allowed.
Water density shall be taken as 9.81kN/m3.
Age factor for increase in strength shall not be considered for design.
The foundation shall be checked for negative pressure on soil due to combined direct &
bending stresses. Negative pressure shall not be allowed on the foundation soil.
Corrosion resistant steel / TMT Fe – 415/ 500as per latest GWSSB approved vendor list
shall be used.
Minimum steel: Design requirements as set out in relevant codes in respect of steel shall
be fully satisfied. However following minimum steel should be provided.
Minimum cover to reinforcement shall be as per I. S. 456 – 2000 and I. S. 3370 (Latest
version).
Design shall be based on accepted bases and well known methods of design as well as
the provision of I.S Codes (Latest edition). However methods based on experimental
investigation on models as mentioned in Clause 18.2 3 in I. S. 456 – 2000 shall not be
allowed. Similarly the methods / practice of design having no documented evidence shall
not be entertained. Only well defined & well known methods of design shall be followed.
1.4 Construction requirement:
The Min. concrete grade for RCC shall be M30. Proportion of concrete ingredients shall be
as per Mix design using weigh batching.
M.S. ladder shall be provided and fixed for access to roof when height of roof from G.L. is
1.0 m and above.
Water level indictor shall be provided and fixed float type /electronic (as specified)
CI pipes & specials shall only be used,
Effective curing shall be carried out as per specifications
1.5 Auxiliary Items of Work:
1. Adequate numbers of C. I. Ventilators (as per GWSSB guidelines) of 150 mm dia shall
be provided on top slab of GSR as directed by Engineer.
2. Adequate number of C.I. Medium class Manhole frame & covers (wt. 53 Kg.) with
locking arrangement shall be provided and fixed in the roof slab of as directed by
Engineer.
GWSSB 7
3. Electronic water level indicator assembly of approved type and make shall be provided
& installed as directed by Engineer.
4. Required number of B. B. masonry / R.C.C chambers of suitable size, with C. I.
manhole frame & cover shall be provided and constructed at suitable locations for
sluice valves and drainage line as directed by Engineer.
5. Inside and Outside surface of tank, exposed faces of columns, braces, beams, bottom
portion of gallery & bottom slab and all exposed surfaces of slab be provided with
smooth finish and then three coats ( one primary coat of white cement and two coats
of snowcem ) of approved shade of snowcem paint as per colour scheme approved by
the Engineer shall be rendered.
6. Internal surface of container including top slab bottom shall be provided with two coats
of epoxy paint (food grade) as directed by Engineer.
7. Letter indicating capacity of tank, name of scheme, year of construction shall be
embossed or engraved on vertical wall of container & shall be painted with suitable
shade of oil paint in two coats as directed by Engineer.
8. On completion of work hydraulic test or water tightness test shall be done as per
standard specification till satisfaction of the Engineer. Water required for testing &
construction shall be made available by the contractor at his cost. If during testing any
damage or leakage or sweating occurs to the structure it will be the responsibility of
the contractor to rectify the same.
9. Drainage arrangement consisting of RCC NP 3 pipes to carry away the wash water
and overflowed water shall be provided upto nearby Nalla or surface drain. The length
of drainage pipe shall be upto 100.0 meters only.
10. Plinth protection in PCC M 15 shall be provided all around the structure as directed by
Engineer.
11. Providing and constructing office at each service reservoir having minimum 13.5 m2
carpet area in R.C.C. framed structure with B.B. masonry walls complete as directed
by Employer.
1.6 Requirement of Auxiliary items of works:
1.6.1 Aluminium Ladder
Aluminium ladder 450 mm wide shall be made up of aluminium rectangular section of 65 x
35 mm (3 mm thick) and 25 mm bars as approved by Engineer. Welded as 300 mm centre
to centre. The ladder shall be provided in two flights i.e. first flight from flat slab at top to
intermediate landing at 3.5 m depth provided & constructed to container wall and second
flight from intermediate landing to bottom slab level. The landing shall be casted
homogeneously with the container wall and shall be 1.0 m x 1.0 m size. It should have G. I.
pipe railing from two sides.
1.6.2 M. S. Ladder
The M.S. ladder shall be provided & fixed to give access to the top slab from bottom slab
gallery. The ladder shall be comprising of 65 mm x 65 mm x 6 mm. M. S. angles placed at
450 mm apart with 16 mm M. S. bars in double rows as steps at 200 mm centre to centre
distance. The ladder shall be properly fixed at site as directed and bottom & top shall be
GWSSB 8
properly embedded in 1:2:4 C.C. block. In order to have stiffness to the ladder cross
supports or stiffeners at suitable intervals as directed shall be provided of suitable M.S.
flats duly embedded in walls and welded to the ladder. The M. S. ladder & supports shall
be provided with three coats of anticorrosive paint as directed.
1.6.3 G. I. Pipe Railing
Hand railing around the walkway (Balcony), stairs and landing shall be fixed on a side
requiring safety. Railing to consist of 25 mm diameter Class B GI pipes in three rows (one
at the top and other at equal interval above finished floor level) and 1000 mm high fixed in
150 mm dia R.C.C. vertical post at a maximum distance of 2000 mm centres with all
accessories like elbows, tees etc. including welding, threading and fixing in cement
concrete floor. Railing shall be painted in three coats of approved oil paint to protect it
against corrosion as directed by Engineer.
1.6.4 Stainless Steel Grating
20 mm Diameter stainless steel bars welded grating with 100 mm c/c spacing, fixed firmly
in the over the outlet pipe and drain pipe.
1.6.5 Electronic Water Level Indicator
The electronic water level indicators are used for direct measurement of liquid level in
tanks. The specifications of electronic water level indicator shall be under:
1. Electrical
Power supply: Operating voltage 230 V AC nominal + 10 %, 50 Hz.
Indication: 16 x 2 alphanumeric LCD
Low level and high level audio alarm (adjustable).
2. Mechanical
Mounting: Wall type.
Size: 255 mm (W) x 182 mm (H).
Enclosure: IP 65 (Splash proof) UV protected virgin plastic cabinet.
The display unit shall be housed in splash proof cabinet to with stand the harsh
environment generally encountered in practice. Clear LCD display shall be easily readable
from a wide viewing angle.
The sensors shall be of sufficient length and resolutions so that the unit can be used
anywhere in premises irrespective of the size & shape of the tank.
Electronic Water level indicator of approved make with constant display placed in office
room shall be provided as directed by Engineer.
1.6.6 Ventilators
Adequate numbers of C. I. Ventilators (as per GWSSB guidelines) of 150 mm dia shall be
provided on top slab of GSR as directed by Engineer.
1.6.7 Plinth Protection
Plinth protection all around the structure shall be provided as directed by Engineer. The
width of plinth protection shall be 1.5 m and shall have slope towards the edge so that the
GWSSB 9
water is drained out and do not enter the foundation. The plinth protection shall be in M 15
(1:2:4) PCC of 150 mm thick. The overburden or top soil from a depth of 0.3 m shall be
removed by excavation & it shall be filled with murrum& boulder in layers. This filling shall
be watered and well rammed as directed by Engineer. On this PCC, M 15 grade shall be
provided and finished smoothly.
All the piping’s like inlet, outlet, washout and over flow and respective fittings like duck foot
bend, bell mouth, crippling flange will be as per approved drawings. The material of all the
piping’s shall be CI as per approved drawings.
1.7 Payment
As per payment schedule in price bid.
GWSSB 10
2 PUMP HOUSE/BUILDING WORKS

All associated civil works like connection to Sump through inlet pipe, pumping machinery
foundation, thrust block in pump house, supporting work to header main ,Jungle cutting ,site
clearance and debris removal etc. complete. (with gantry girder as per mechanical
requirement), Height of pump house should be minimum 6.0 m from floor level to bottom of
beam, reinforcement / steels should be TMT steel Fe-415 / Fe-500 as per relevant IS only
to be used
2.1 Description
Ancillary works such as site grading, site drainage; fencing and gates for outdoor substation
etc. as described under specifications for Civil & Building Works shall be undertaken.
The following are the design requirements for all reinforced or plain concrete structures:
a) All buildings shall be designed to resist the worst combination of the loads / stresses
under test and working conditions; these include dead load, live load, wind load, seismic
load, stresses due to temperature changes, shrinkage and creep in materials, dynamic
loads, impact load and other specific loads.
b) All reinforced concrete structural design shall generally conform to the following
publications of the Bureau of Indian Standards:
I.S. 456 Code of Practice for plain and reinforced concrete
I.S. 875 Code of Practice for design loads for buildings and structures (Part 1 to 5)
I.S. 1893 Criteria for earthquake resistant design of structures
I.S. 2974 Code of Practice for design & construction of machine foundations (Part 1 to 4)
c) All building works shall be of reinforced concrete framework.
d) All binding and levelling concrete shall be a minimum 100 mm thick in concrete grade
M15 or in concrete mix 1:2:4 to be used.
e) All internal masonry surfaces finish shall have 12 mm thick plain faced cement plaster in
cement mortar (1:4) with neat lime or neeru finish on top. Over this, one coat of primer
and two coats of plastic emulsion paint of approved quality and shade shall be provided.
f) All external masonry surfaces shall have 15 mm thick sand faced cement plaster in
cement mortar (1:3) in two coats. Waterproofing compound of approved make and
quality shall be added to the cement mortar in proportions as specified by the
manufacturer.
g) All external surfaces above ground level shall have one coat of primer and two coats of
waterproof cement based paint (snowcem) of approved quality and shade. A coat of
silicone water repellent paint shall also be applied thereon.
h) All structural reinforced concrete for water retaining structures shall be of a minimum
M30 grade with a maximum 40 mm aggregate size for footings and base slabs of
thickness more than 200mm and with a maximum 20 mm aggregate size for all other
structural members. For non water retaining structures the concrete shall be of M 25
GWSSB 11
grade with a maximum 20 mm aggregate size. The water retaining structures shall have
to be designed as per IS: 3370 (Part I-IV).
i) The reinforced concrete shall have minimum cement content IS: 456-2000/IS 3370 latest
revision.
j) The reinforcement to be used shall be TMT reinforcement of grade Fe -415 / Fe-500 of
reputed make, conforming to IS: 1786.
k) The minimum reinforcement for water retaining structures in each direction should be as
per IS 3370. For Non water retaining structure IS 456.The minimum clear cover to all
reinforcement shall be as per latest IS codes.
l) The minimum size of secondary reinforcement shall be 8mm
m) All buildings shall have a minimum 1 meter wide, 100 mm thick plinth protection paving
in M15 grade concrete or stone slabs/tiles. All plinth protection shall be supported on well
compacted strata.
n) Any structure or pipeline crossing below roads shall be designed for Class A of IRC
loading.
o) The bridges & bridge supporting structures shall be designed to safely withstand the
loading.
p) All pipes & conduits lay below the structural plinth & road works shall be embedded in
reinforced concrete of grade M15 of minimum thickness 150 mm.
q) Approved quality water proofing compound (chloride free) shall be added during
concreting of all liquid containing structure in the proportions specified by manufacturer
or 2 % by weight of cement whichever is higher.
r) The wall and floor panels shall be poured in sequential order with a minimum time gap of
4 days.
s) Flooring should be vitrified tiles first quality.
t) For roofing drainage, cast iron rainwater downtakes with C.I. bell mouth and C.I. grating
at top shall be provided. For roof areas up to 100 sq.m minimum two nos. 100 mm
diameter downtake pipes shall be provided. For every additional area of 100 sq.m or part
thereof, at least one no. 100 mm dia. downtake pipe shall be provided.
u) Top surfaces of chajjas and canopies shall be made waterproof by providing a screed
layer of adequate slope or application of an approved roof membrane and sloped to
drain the rain water. Chajjas, canopies and roof projections shall have drip moulds.
v) Building plinth shall be minimum 600 mm above average finished ground level around
building.
w) All doors, windows, rolling shutters shall have lintels above. Chajja projection to lintels on
external walls shall be such as to prevent the rain water splashing into the building.
x) All windows and ventilators shall have 25 mm thick marble stone sills bedded in cement
mortar (1:3)
GWSSB 12
y) All concrete channels and ducts used for conveying liquid shall have inside finish of type
F2. The width of concrete channels shall not be less than 500 mm. All open channels
shall be provided with hand railings.
z) Kerbs to be provided below the hand railing on the catwalks/pathways should be as per
relevant sections of Factory Act.
aa) All rooms in the buildings shall be provided with appropriate sign boards indicating the
function of the rooms involved.
bb) Wherever equipment and machinery are to be moved for inspection, servicing,
replacement etc., suitable movable gantry in the form of EOT / HOT crane shall be
provided. Minimum capacity of 2 tonnes or more as required shall be provided for
monorail and as per approval of engineer-in-charge.
cc) The design of buildings shall be suitable for the climatic conditions existing on site.
Buildings shall as far as is possible permit the entry of natural light.
dd) Emergency exit doorways with Signboards shall be provided from all buildings in order to
comply with local and international regulations. Stairways and paved areas shall be
provided at the exit points.
ee) Toilet blocks in pump house buildings shall be provided with a sink with one drinking
water taps of 15 mm size with adequate inlet and outlet connections.
ff) The side walls of buildings shall, comprise at least 15% ventilated brickwork or louvers.
Ventilated brickwork or louvers shall not be used where the ingress of driven rain could
affect equipment or stored materials.
gg) All staircases shall have 25 mm thick chequered mosaic or chequered vitrified tiles for
treads and 25 mm thick plain mosaic tiles of approved shade for risers set in cement
mortar or lime mortar to give an overall thickness of 50 mm.
hh) All concrete stairs shall have aluminum nosing over 2 mm thick rubber strip of width
same as nosing for the full length of the tread. Nosing shall be fixed with countersunk
screws.
Stairways shall be provided to permit access between different levels within buildings.
All roof tops and overhead tanks shall be made accessible with ladder provision. Vertical
ladders fitted with landing point extensions will be permitted where considered
appropriate by the client to access areas not frequently visited.
ii) All floor cut-outs and cable ducts, etc. shall be covered with precast concrete covers in
outdoor areas and mild steel chequered plates of adequate thickness in indoor areas. All
uncovered openings shall be protected with M.S. hand railing of 32 NB (M).
jj) All staircases shall be provided with 32 NB (M) galvanized M.S. pipe hand railing for
protection.
kk) The reinforced concrete roofs shall be made waterproof by application of an approved
roof polythene / bitumen membrane. The finished roof surface shall have adequate slope
to drain quickly the rain water.
GWSSB 13
2.3 Construction Requirement

The general specification of cement, sand, brick, metal, water, mixing, placing and curing etc
shall be as per general specifications laid down in this contract or latest IS standard.
2.4 Method of Measurement
The measurement shall be recorded based on stages of works completed.
2.5 Payment
GWSSB 14
3 OFFICE ROOM
Construction of Office room at each headwork including all material and labour with all
facilities providing and supplying required furniture's as directed by Engineer in Charge etc.
Complete.
The following items shall be included in the administrative building.
Item Description Unit No
A OfficefurnitureofGodrej/orsimilar
approvedquality
CeilingFan48”size Standard Company No 1
Desk with 3 drawers with locks for each plan No 1

dimension of desk 1500 mm x 900 mm
approx.
Revolving Chairs with Tapestry Cushion No 1

on seat, back & handle
3.1 REQUIREMENTS OF CONSTRUCTION DETAILS FOR OFFICE ROOM

The construction requirements for Office room building viz. flooring, ceiling, walls etc.:
1. All internal masonry surfaces finish shall have 12 mm thick plain faced cement plaster in
2. All external masonry surfaces shall have 15 mm thick sand faced cement plaster in
manufacturer.
3. All external surfaces above ground level shall have one coat of primer and two coats of
4. Room areas, walls and ceilings, shall have one coat of primer and two coats of plastic
emulsion paint.
5. For office building foundation and plinth will be in Framed structure where as all walls for
super structure will be 230 mm thick in Brick masonry in C.M. 1:6..
6. The flooring in all areas shall be in 600 mm x 600 mm x 15-mm thick vitrified tiles placed
in C.M. to give overall thickness of 50mm.
7. All staircases shall have 25 mm thick mosaic tiles for treads and 25 mm thick plain
mosaic tiles of approved shade for risers set in cement mortar or lime mortar to give an
overall thickness of 50 mm.
GWSSB 15
8. The reinforced concrete roofs shall be made waterproof by application of an approved

roof polythene / bitumen membrane. The finished roof surface shall have adequate
slope to drain quickly the rainwater to R.W down take inlet points.
9. Top surfaces of chajjas and canopies shall be made waterproof by providing a screed
layer of adequate slope or application of an approved roof membrane and sloped to
drain the rainwater. Chajjas, canopies and roof projections shall have drip moulds.
10. Building plinth shall be minimum 1000 mm above average finished ground level around
building.
11. All windows and ventilators shall have 25 mm thick marble stone sills bedded in cement
mortar (1:3)
12. The office building includes the scope of water supply and sanitation facilities including
the 1000 liters capacity (minimum) of ISI marked PVC tank.
13. Agency shall provide sufficient number of 40W tube lights and 36W LED electric bulb of
approved quality as per instruction of engineer in charge.

3.3 Payment
As per the payment schedule.
GWSSB 16
4 APPROACH ROAD
 Box cutting the road surface to proper slope and camber for making a base for road
work including removing the excavated stuff and depositing on the road side slope as
directed up to 50 meter lead
 Providing and laying cement concrete 1:5:10(1 cement:5 coarse sand:10 hand broken
stone aggregate 40 mm nominal size)and curing complete excluding form work
4.1 Structural Concrete:

Structural Concrete shall be as per IS: 456-2000: Clause-6.
4.2 Concrete Making Materials
 Cement: Ordinary Portland Cement conforming to IS: 269, IS: 8112, IS: 12269; Portland
Slag Cement conforming to IS: 455, Portland Pozzolana Cement as per IS: 1489 (Part-
1)
 Mineral Admixtures: Fly Ash conforming to Grade-I of IS: 3812
 Aggregates: Aggregates shall comply with requirements of IS: 383.The size of

Aggregate: The nominal maximum size of coarse aggregate should be 20mm.
 Water: Water as per Clause 5.4 of IS: 456 2000.
 Admixtures: Admixtures shall comply with IS: 9103
 Reinforcement: Reinforcement shall be mild steel and medium tensile steel bars
conforming to IS: 432 (Part-1), high strength deformed steel bars conforming to 15:1786
 Storage of Materials: Storage of Materials shall be as per IS: 4082
 Production of Concrete as per Clause 10 of IS: 456.

4.3 Mix Design
The mix shall be approved by Engineer-in-Charge so as to obtain the following mean
strength that exceeds the minimum specified flexural strength by 1.64 times the designed
standard deviation.
Minimum works beam
Flexural strength at 28 days = 300 kg/sqm. for M-30 or specified in item
Designed standard deviation = 60 kg/sqm. for M-30 or for specified grade(s)
Design flexural strength
at 28 days = 300+60x1.64 = 398.4 kg/sqm. (f + 1.64 s )
= says 400 kg.
Water cement ratio by weight = 0.5
Minimum slump not more than 25 mm
GWSSB 17
4.4 Statistical Field Check

Samples of concrete shall be taken at the mixer and works beams, made, cured and
tested in accordance with IS 1199 and IS 516.
4.5 Slump Test
The test shall be carried out as per IS 1199. A slump test shall be carried out at each
mixer at least one in fifty batches mixed or more frequently if directed by the Engineer-in-
Charge. Any batch from which slump test is being made shall not be transferred to the
place of laying till the slump test has been completed. Not only the batch which gives a
slumps in excess of that specified shall be rejected but the concrete already laid
immediately preceding the batch tested upto the nearest last transverse joint may be
rejected by the Engineer-in-Charge or his subordinate, if he is satisfied that such
preceding batches were substandard in this respect. The decision of the Engineer-in-
Charge in this respect shall be final and binding on the contractor. Such rejected concrete
shall be removed by the contractor immediately and replaced with proper slump concrete
at his cost and expense.
4.6 Steel Forms
All side forms shall be of mild steel. The steel forms shall be of M.S. Channel sections
and their depth shall be equal to the thickness of the pavement.
4.7 Setting of Forms
(a) Setting of forms shall be according to the slab plan subject to the approval of
Engineer-in-Charge and concreting shall not commence until the setting of forms is
approved.
(b) Forms shall be set for at least 50 metres in advance of the point where the concrete is
being laid and shall not be removed until at least 12 hrs. of placing of the concrete or
longer if in the opinion of Engineer-in-Charge is necessary.
(c) After setting, the working faces shall be thoroughly oiled by using approved oil before
concrete is placed against them.
(d) The pavement joints of overlay layer would overlap with the joints of underlay cement
concrete.
4.8 Compaction of Concrete
Compaction shall be carried out by electrically (or) diesel operated needle and screed
vibrators as stipulated hereafter. Needle vibrator should be used all over the area for
obtaining initial compaction of concrete. These should be of diameter not less than 4.5
cm. If the vibrator is pneumatic the pressure must not be below 4 kg/sq.cm. If electrically
operated, they should have a minimum frequency of 3500 impulses per minute.
4.9 Finishing of Concrete
During compaction, any low or high spots shall be made up by adding or removing
concrete. After longitudinal floating has been completed but while concrete is still plastic,
the slab surface shall be tested for trueness with a 3 m straight edge. Any depressions or
high spots showing departure from the true surface shall be immediately rectified. High
spots shall be cut down and refinished. Depressions shall be enlarged to about 8-10 cm
and filled up with fresh concrete, compacted and finished.
GWSSB 18
4.10 Initial Curing

Immediately after completion of the finishing operations, the surface of the pavement shall
be entirely covered with wetted burlap, cotton or jute mats. The mats used shall be of
such length (or width) that as laid they shall extend at least 45 cm beyond the edges of
the slab. The mats shall be placed so that the entire surface and both edges of the slab
are completely covered. This covering shall be placed as soon as, in the judgment of the
Engineer-in-Charge the concrete has set sufficiently to prevent damage to the surface
prior to being placed, the mats shall be thoroughly saturated with water and shall be
placed with the wettest side down. The mats shall be so placed and weighed down as to
cause them to remain in intimate contact with the surface covered, and the covering shall
be maintained full wetted and in position for 24 hours after the concrete has been placed
or until the concrete is sufficiently hard to be walked on without suffering damage. Water
shall be gently sprayed so as to avoid damage to the fresh concrete. If it becomes
necessary to remove a mat for any reason, the concrete slab shall not be exposed for a
period of more than half an hour.
4.11 Final Curing
Upon the removal of the burlaps, the slab shall be thoroughly wetted and then cured as
follows:-
All joints shall be filled with filler in order to prevent the edges of joints from getting
damaged and entry of clay materials into the joints during final curing. Exposed edges of
the slab shall be banked with a substantial berm of earth. Upon the slab shall then be laid
a system of transverse and longitudinal dykes of clay about 50 mm high immediately
covered with a blanket of sandy soil free from stones to prevent the drying up and
cracking of clay. The rest of slab shall then be covered with sufficient sandy soil so as to
produce a blanket of earth not less than 40 mm deep after wetting. The earth covering
shall be thoroughly wetted while it is being placed on the surface and against the sides of
the slab and kept thoroughly saturated with water for 21 days and thoroughly wetted down
during the morning of the 22nd day and shall thereafter remain in place until the concrete
has attained the required strength and permission is given by the Engineer-in-Charge.
Thereafter the covering shall be removed and the pavement cleaned and swept. If the
earth covering becomes displaced during the curing period, it shall be replaced to the
original depth and re saturated.
4.12 Measurements
For the purpose of ascertaining the quantity of concrete in the pavement, thickness shall
be measured by means of a scale correct to the nearest 2 mm. The thickness of the
concrete pavement slabs shall be taken on either side of the pavement at each dummy
joint at four corners of the slab immediately after removal of the side forms. In case the
average thickness of the slab exceeds the specified thickness, payment shall be restricted
to the specified thickness.
The dimensions of each slab of pavement shall be measured as follows to the nearest 5
mm.
(a) Length
(i) Between the end of a pavement to the centre line of the expansion joints.
(ii) Between the centre lines of consecutive expansion joints.
(b) Width
GWSSB 19
(i) Between the edge of a pavement and the centre line of the construction joints.
(ii) Between the centre lines of construction joints and expansion joints.
(iii) Between the centre lines of consecutive construction joints.
Note: The quantity of concrete in the pavement slab shall be worked out by multiplying
the area of the slab and its average thickness or specified thickness whichever is less.
No deduction shall be made for any joints in the concrete slab.
Measurements of concrete slabs shall be recorded jointly by the Engineer-in-Charge or
his authorised subordinate and the contractor or his authorised agent.
4.13 Rate
The rate of the item for concrete in pavement shall include the cost of all materials and
labour including charges for machinery tools & plants required in all the operations
described above. The rate also includes all cost of setting up the laboratory at site and
carrying out the quality control measures/tests enumerated above by the contractor at his
own cost in the presence of Engineer-in- Charge or his authorized representative and
submission of test results on completion of tests to the Engineer-in-Charge thereof

The measurement shall be recorded based as per given in price bid.
4.15 Payment
GWSSB 20
5 COMPOUND WALL
 Construction of compound wall in brick masonry C:M 1:6, Min 23 cm. thick & 1.50 m
height above G.L, Providing and fixing 1.2M high fencing with 2M long M.S. Angle Post
minimum 40x40x6 mm and oil painting 3 coats fixed at 2.5meter c/c with seven
horizontal rows of galvanised steel barbed wire weighing 9.39kg/100 meters strained
and fixed to post with GI staples fitted inside of compound wall. 10 cm. Thick coping in
C:C 1:3:6 on top of wall & Plinth Beam above GL both side 12 mm.thick cement plaster
in C.M. 1:3, including painting as per direction of engineer in charge. Works, including
Excavation for foundation of wall and column, P.C.C. 1:3:6 below beam & column
footing, RCC Column with footing as per drawing. (Agency should design all the
components as per latest IS codes.)
 Height of masonary compound wall is 1.80mt from the FGL. Fencing should be provided
on the top of masonary wall using MS angles 40x40x6 at every 2m distance of height
1.2mt and containing 6 nos of bar bard wire row of gauge 12 as directed by Engineer-in-
charge
 Approximately every 3mt distance brick colums to be constructed of size 35x35cm

where as wall thickness will be 230mm.
 Two nos of M.S.Fabricated gates of size 3.50x1.8 mt size with one wicket gate should
be provieded as per design by Engineer-in-charge.
 Below FGL the thickness of Beam and Masonary will be 350mm.
 Providing and Fixing MS Gate made from MS angles, Channels and Flats including all
labour and material cost with painting and fixing at site of work including carting, loading,
un loading etc. complete. & As per instruction & design given by EIC.
 Painting two coats (excluding priming coat) on new steel and other metal surface with
synthetic enamel paint, brushing to give an even shade including cleaning the surface
of all dirt, dust and other foreign matter.
Contractor shall obtain Engineer in Charge approval before start of the work.
The general specification of brick, cement, sand, metal ,water, mixing, placing and curing
etc shall be as per general specifications laid down in this contract.
The measurement shall be recorded based length of compound wall constructed.
5.2 Payment
As per payment schedule in price bid
GWSSB 21
6 ELECTRICAL ROOM
Designing (aesthetically) and Constructing RCC framed Electrical Room in M: 25 mix. as
per design , requirement and specification at various site inclusive. all associated civil
works like Cable trench, Jungle cutting, site clearance and debris removal etc. complete.
Height of Electrical room should be minimum 4.5 m from bottom floor level to bottom of
beam, reinforcement / steels should be TMT steel Fe-415 / Fe-500 as per relevant IS
only to be used.
6.1 Description
Ancillary works such as site grading, site drainage; fencing and gates for outdoor
substation etc. as described under specifications for Civil & Building Works shall be
undertaken.
The following are the design requirements for all reinforced or plain concrete structures:
a) All binding and levelling concrete shall be a minimum 100 mm thick in concrete grade
M15 or in concrete mix 1:2:4 to be used.
b) All internal masonry surfaces finish shall have 12 mm thick plain faced cement plaster in
c) All external masonry surfaces shall have 15 mm thick sand faced cement plaster in
manufacturer.
d) All external surfaces above ground level shall have one coat of primer and two coats of
e) All structural reinforced concrete for water retaining structures shall be of a minimum
M30 grade with a maximum 40 mm aggregate size for footings and base slabs of
thickness more than 450mm and with a maximum 20 mm aggregate size for all other
structural members. For non water retaining structures the concrete shall be of M 25
grade with a maximum 20 mm aggregate size. The water retaining structures shall have
to be designed as per IS: 3370 (Part I-IV).
f) The reinforced concrete shall have minimum cement content IS: 456-2000/IS 3370.
g) The reinforcement to be used shall be TMT reinforcement of grade Fe -415 / Fe-500 of
reputed make, conforming to IS: 1786.
h) The minimum reinforcement for water retaining structures in each direction should be as
per IS 3370. For Non water retaining structure IS 456.The minimum clear cover to all
reinforcement shall be as per latest IS codes.
i) The minimum size of secondary reinforcement shall be 8mm
j) All buildings shall have a minimum 1 meter wide, 100 mm thick plinth protection paving
in M15 grade concrete or stone slabs/tiles. All plinth protection shall be supported on well
compacted strata.
GWSSB 22
k) Any structure or pipeline crossing below roads shall be designed for Class A of IRC
loading.
l) The bridges & bridge supporting structures shall be designed to safely withstand the
loading.
m) All pipes & conduits laid below the structural plinth & road works shall be embedded in
reinforced concrete of grade M15 of minimum thickness 150 mm.
n) Approved quality water proofing compound (chloride free) shall be added during
concreting of all liquid containing structure in the proportions specified by manufacturer
or 2 % by weight of cement whichever is higher.
o) The wall and floor panels shall be poured in sequential order with a minimum time gap
of 4 days.
p) Flooring should be vitrified tiles first quality.
6.3 Construction Requirement
The general specification of cement, sand, brick, metal, water, mixing, placing and curing
etc shall be as per general specifications laid down in this contract or latest IS standard.
6.5 Payment
GWSSB 23
7 THRUST BLOCK & PEDESTAL

1. Excavation for foundation including throwing the excavated stuff upto a lead of 90M. In
all strata for depth 0.0 meter. To 1.5meter.
2. PCC : Providing and laying in foundation cement concrete 1:3:6 (1 cement:3 coarse
sand:6 hand broken aggregates 40 mm nominal size) and curing complete excluding
cost of form work in foundation and plinth.
3. Providing and cast in situ c.c.in grade M.20 using, granite, quantizite trap metal of size 6
mm to 20mm for RCC work including scaffolding centering formwork, needle vibrated
consolidation curing and hydraulic testing etc. comp.(excluding cost of reinforcement
and neat finishing) with centering and shuttering etc complete for thrust block
(i) Footing (without formwork)
4. Providing and cast in situ c.c.in grade M.20 using, granite, quantizite trap metal of size 6
mm to 20mm for RCC work including scaffolding centering formwork, needle vibrated
consolidation curing and hydraulic testing etc. comp.(excluding cost of reinforcement
and neat finishing) with centering and shuttering etc complete for thrust block
(ii) Column
5. Supplying cutting bending binding and placing in position steel as per plan and design
and as per IS 2502 including cost of steel and binding wire for reservoirs only including
lift up to 6mtr.height.
The thrust block shall be designed as per the design pressure in the Pipeline and per the
standard guidelines provided in CIRIA Report 128_Guide to Design of Thrust Blocks for
Burried Pressure Pipelines & DIPRA with its latest revision.
The general specification of Excavation, CC- M10, RCC-M20, formwork, Steel
reinforcement etc shall be as per General Specifications laid down in this contract.
The measurement shall be recorded based on the unit provided in Price schedule in the
Bid document.
7.2 Payment
Payment shall be provided as per payment schedule and price bid in the Bid document.
as per complete construction of the item as per Price bid and specification and as per
instruction by Engineer In Charge.
GWSSB 24
8 ENCASING PIPE LINE.

Providing C.C.M.10 for encasing pipes using trap metal size 12 mm to 50 mm form work
curing consolidation etc. complete. Using trap metal of 20 mm size.
The general specification of Excavation, shall be as per general specifications laid down
in this contract.
The measurement shall be recorded based on the unit provided in Price schedule in the
Bid document.
8.2 Payment
GWSSB 25
9 VALVE CHAMBER
Construction of valves chambers as per design to satisfy all the necessary check given in
the latest IS codes , in brick or bela stone masonry, locally available in C. M. 1:6, 100mm
thick P.C.C in 1:3:6 with Foundation concrete / base slab min100 mm thick or as per the
design ,grade of concrete 1:2:4, inside cement plaster in C. M. 1:3 and cement pointing
outside in C. M. 1:3 and top cover of precast RCC slab 100 mm thick (with key hole in two
parts, each with handles or MS Bar etc. complete as given size) Upto 1 Meter depth from
G. L. to pipe invert level including complete civil works but excluding cost of excavation and
refilling. With cast in situ RCC slab in one single piece with fixing of CI-MH Frame and
cover (excluding cost of CI-MH Frame and cover) with minimum 230 mm thick or as per the
design , brick masonry wall in C.M.1:6 .
Additional excavation required to be done shall be carried out as per instruction of

Engineer-in-charge. For foundation chamber 15 cm. thick 1:3:6 PCC shall be provided and
23 cm. min or as per design requirement up to 1.5 m. depth and beyond 1.5 m. depth 35
cm thick min or as per design requirement BB masonry walls in CM 1:6 shall be
constructed.
Second Class bricks of Standard size shall be brought by the Contractor & shall got
approval before use in the work from the Engineer-in-charge.
12 mm thick cement plaster in CM 1:3 shall be provided on inside and outside of walls up
to 20 cm below from G.L. Cement pointing in CM 1:3 shall be provided for outside below
G.L. from 20 cm.
20 mm dia MS bar steps shall be provided and fixed in wall at 30 cm c/c for facilitating
access into the chamber. First step should be at a depth of 0.5 m from top and last step
should be 0.5 m above bottom.
Chamber shall be covered with 100 mm thick RCC 1:2:4 pre cast or cast in situ slab in two
parts with keyhole to insert key for operation.
Reinforcement for the cover slab shall be provided considering heavy traffic load.
Curing of concrete, BB masonry , RCC etc. shall be done using chemical or water for 14
days.
12 mm dia MS bar handles minimum two nos. shall be provided to each piece of slab
during the time of casting of slab.
Sides of chamber shall be refilled properly with selected excavated earth.
All the above items shall be carried out in workman like manner as per prevalent sound
engineering practice and instruction of Engineer-in-charge.
Valve chamber shall be constructed with as per typical drawing in Volume – V - Drawings.
Contractor to submit the valve chamber drawings based on site conditions to review and
approval before execution.
Valve chambers shall be constructed at places as shown on relevant drawings and as
directed by the Engineer-in-charge.
GWSSB 26
9.1 Excavation
Excavation, shoring, dewatering etc. for the pits of manholes, laying of pipes and
fittings/specials shall be done in accordance with Employer’s Requirements described
elsewhere in the document.
9.2 Plain Cement Concrete:
The water, sand, cement & stone aggregate of 25mm to 40 mm nominal size shall be used
of approved quality as per standard specification in I.S. 456. Detail specification of
materials as given in General Technical Specification shall be observed.
Workmanship: Before starting concrete the bed of foundation trenches shall be cleared of
all loose materials, levelled, watered and rammed as directed.
Mixing: The concrete shall be mixed in a mechanical mixer at the site of work. Hand mixing
may however be allowed for smaller quality of work if approved by the Engineer-in-charge.
When hand mixing is permitted by the Engineer-in-charge in case of breakdown of
machineries and in the interest of the work, it shall be carried out on a water tight platform
and shall be taken to ensure that mixing is continued until the mass is uniform in colour and
consistency. However, in such cases 10% more cement than otherwise required shall have
to be used without any extra cost. The mixing in mechanical mixer shall be done for a
period of 1.5 to 2 minutes. The quantity of water shall be just sufficient to produce a
dense concrete of required workability for the purpose.
Transporting and placing the concrete: The concrete shall be handed from the place of
mixing to the final position in not more than 15 minutes by the method as directed and shall
be placed into the final position, compacted and finished within 30 minutes of mixing with
water i.e. before the setting commences.
The concrete shall be laid in layers of 15 cm to 20 cm
Compacting: The concrete shall be rammed rapidly with heavy iron rammers to get the
required compaction and to allow all the interstices to be filled with mortar.
Curing: After the final set, concrete shall be kept continuously wet, if required by pounding
for a period of not less than 7 days from the date of placement.
9.3 Cement Plaster
The proportion of the cement mortar shall be as approved on relevant drawings. Cement
shall be mixed thoroughly in dry condition and then just enough water added to obtain a
workable consistency. The quality of water, sand and cement shall be as per relevant I.S.
The mortar thus mixed shall be used immediately and in no case shall the mortar be
allowed to remain for more than 25 minutes after mixing with water.
Curing of plaster shall be started as soon as the applied plaster has hardened enough so
as not to be damaged. Curing shall be done by continuously applying water in a fine spray
and shall be carried out for at least 7 days.
9.4 Scaffolding
For brick work in chamber, single scaffolding shall be permitted. In such cases, the inner
end of the horizontal scaffolding pole shall rest in a hole provided only in the header course
for the purpose. Only one header for each pole shall be left out. Such holes for scaffolding
shall, however, not are allowed in pillars/columns less than one meter in width, or
GWSSB 27
immediately near the skew backs of arches. The holes left in masonry works for scaffolding
purpose shall be filled and made good before plastering.
The detailed specification shall be as per general specification of this tender document.
The measurement shall be recorded based on number of valve chamber constructed at

site.
9.6 Payment
GWSSB 28
10 Road Crossing/Railway Crossing/Gas pipeline Crossings:

Drilling of specified mm diameter Horizontal borehole for water main pipeline under the road
including in all strata with required length including providing & fixing of specified diameter
MS casing pipe with welding pushing etc complete with all material labour fabrication,
hydraulic testing of pipe etc complete main with/without water main .If the quantity
considered in item increased or decreased as per site condition then it will be paid or
deducted on running meters basis derived from amount quoted for total length in item on pro
rata basis.
At, Road , Railway ,& canal crossings the work shall be performed to the specifications Of
local authorities or such public bodies as may be in charge (S) of Roads, Railway and
Canals to be crossed. In case, however the minimum requirements of the governing
agencies are less than Those set out in the drawing or the specifications given herein, then
the Requirements given in the drawings and the specifications given for encased line Shall
be followed. At all crossings the carrier pipe shall be laid straight without bends so that if
Necessary the pipe at a later date may be replaced without cutting the casing. The Carried
pipe shall extend at least 2 meters beyond the end of casing pipe at either End. At Road
crossings the TENDERER shall eliminate unnecessary bending of pipe to Conform to the
contour of ground by gradually deepening the ditch at such Approaches as directed by the
engineer – in - charge.
Temporary bridge Work ensuring the safety of the traffic aids and safeguards for protection
of the Public safety, or he shall provide suitable diversions as desired by the engineer in
Charge. At all Roads, Railway pipeline crossings shall be bored with horizontal boring
machine. The method of carrying out a cased crossing by boring for various crossings on
this Pipeline route shall be jointly inspected by the representative of the COMPANY and
TENDERER for each category of work prior to commencement of actual work. Pipeline
under Road track, an applicable portion of the right of way shall be encased in accordance
with the specification. This item of work shall include, necessary clearing and grading
required therefore, trenching to the depths and widths required, welding of casing and
jointing of carrier pipes, testing, lowering in, Installation of vent assembles, end seals,
insulator and all other fittings that may be Required, backfilling, clean up, complete
restoration to the original condition and Further strengthening and protective works as may
be required. The work shall be carried out in accordance with the drawings and as directed
by the engineer-in-Charge. For various operations mentioned above, the specifications
pertaining to these operations shall apply in addition to the specifications given herein.
In case of line to be laid by open cut, engineer-in-charge may at his discretion permit open-
cuts to be made for the installation of casing provided, however, that the TENDERER shall
procure the necessary permit / license for the same from competent authority. The
TENDERER shall produce a certificate in writing from concerned authorities for its
satisfactory restoration and payment therefore.
(a) At road and canal crossings the work shall be performed to the specifications of local
authorities or such public bodies as may be in charge (S) of roads and canals to be
crossed.
(b) In case, however the minimum requirements of the governing agencies are less than
those set out in the drawing or the specifications given herein, then the requirements
given in the drawings and the specifications given for encased line shall be followed.
(c) Where as the casing pipe in the case of encased line to be laid normal by boring,
tunneling, engineer-in-charge may at his discretion permit open-cuts to be made for
the installation of casing provided, however, that the TENDERER shall procure the
necessary permit / license for the same from competent authority. At locations wherein
GWSSB 29
the open cut methods are permitted, the TENDERER shall pass the carrier pipe
through the casing located in the trench after the approval of the engineer-in-charge in
writing , if Open Cut method is not permitted by authority, pipe is to be laid through
Push Through Method. and care shall be exercised to avoid damage to pipe coating
and wrapping during this operation. The TENDERER shall produce a certificate in
writing from concerned authorities for its satisfactory restoration and payment
therefore.
(d) At all crossings the carrier pipe shall be laid straight without bends so that if necessary
the pipe at a later date may be replaced without cutting the casing. The carried pipe
shall extend at least 2 meters beyond the end of casing pipe at either end.
(e) At road crossings the TENDERER shall eliminate unnecessary bending of pipe to
conform to the contour of ground by gradually deepening the ditch at such approaches
as directed by the engineer-in-charge. Where the installation of the casing has been
made by open cut TENDERER shall install suitable temporary bridge work ensuring
the safety of the traffic aids and safeguards for protection of the public safety, or he
shall provide suitable diversions as desired by the engineer-in-charge.
(f) The method of carrying out a cased crossing by boring for various crossings on this
pipeline route shall be jointly inspected by the representative of the COMPANY and
TENDERER for each category of work prior to commencement of actual work.
(g) Pipeline under Road Track and irrigation canal an applicable portion of the right-of-way
shall be encased in accordance with the specification. This item of work shall include,
necessary clearing and grading required therefore, trenching to the depths and widths
required, welding of casing and carrier pipes, testing, lowering in, installation of vent
assembles, end seals, insulator and all other fittings that may be required, backfilling,
clean up, complete restoration to the original condition and further strengthening and
protective works as may be required. The work shall be carried out in accordance with
the drawings and as directed by the engineer-in-charge. For various operations
mentioned above, the specifications pertaining to these operations shall apply in
addition to the specifications given herein.
The TENDERER shall be permitted to use William Sons type Neoprene seals in place of
concrete end seals for the crossings. The item shall be procured by the TENDERER
himself as per the provisions under the appropriate head of work in case TENDERER so
desires. The representative of the COMPANY may also be associated to determine the
quality of the material and its delivery schedule from the open market. However, the
particular work defined under the proper head shall not be delayed on account of non-
availability of Neoprene end seals. In such case, concrete seals may be provided.
On both ends of pushing concrete supports are to be provided as per direction of engineer-
in-charge.
Measurement and Payment
The items of the work shall be measured and paid on the running meter basis completed in
all respects including all materials, labours, jointing materials, tools, transportation, taxes and
other including items for completion of work after receiving no due certificate from concern
authority.
GWSSB 30
 MDPE PIPE FOR PLOT SERVICE CONNECTIONS

GENERAL
The service connection shall include MDPE pipe of required length, rubber gasket,
Ferrule, Nuts, bolts for fixing saddle or service clamp as required.
The MDPE pipes shall conform to ISO DP 4427. The ferrule for connection shall
generally conform to IS: 2692. It shall be of non-ferrous material with a CI bell mouth
cover and shall be fitted with a screw and plug or valve capable of completely
shutting off the water supply to the communication pipe if and when required. Service
pipes less than 50mm bore may be connected to mains by means of right angled
screw down ferrule.
The thickness of MS flats used for fabricating service clamps should be minimum
4mm to enhance the life of the clamp. The thickness of rubber gasket (packing
material) should be minimum 3mm as per IS: 5382. MS bolts and nuts to be used for
fixing the saddle or service clamp should conform to IS: 1363. GI pipes shall conform
to IS 1239, heavy duty class C.
For HDPE pipe saddle, the MDPE pipes shall be connected to the saddle using
socket and spigot arrangement / with any other arrangement as specified by the
saddle supplier. All necessary fitting required for the connections shall be deemed
part of the saddle supply.
CONNECTION AT MAIN
Boring on water main should be done on the top of main. A manual drilling and
tapping machine can be used for this purpose. A bore can be drilled and tapped on
DI / HDPE main and ferrule can be screwed directly into the bore. The size of the
ferrule should not exceed a quarter of the nominal diameter of the main and also be
less than the size of the communication pipe.
The ferrule should be so set in the main that the communication pipe leads off in line
with the main before curving round right angled in to its proper course. This allows for
further tightening of the ferrule in the main in case of settlement of communication
pipe. Minimum cover to MDPE pipes inside the property should be 20 to 30 cm along
the road crossing adequate cover should be provided before the pipe enters the
property boundary. The MDPE pipe pieces shall be made out of pipes conforming to
ISO 4427: 1996. GI encasing of MDPE pipes shall be provided where ever required
as per the direction of Engineer in charge.
SERVICE CONNECTIONS (PLOT SERVICE CONNECTIONS)-FERRULES AND STRAPS

ELECTRO FUSION SADDLE
MATERIAL
Electro-fusion saddle shall be of PE80 / PE10, SDR 11/17 and shall be of reputed
make provided as per the drawings for various sizes to the satisfaction of the
Engineer In Charge. Electro-fusion Branch Saddles shall be designed and
manufactured in accordance with ASTM F-1055 for use with pipe conforming to
ASTM D2513/3035, F-714 and with Butt fittings conforming to ASTM D3261 as
applicable
GWSSB 31
Outlets from tapping tees and branch saddles shall be spigotted in accordance with
clause 6.3 or with electro-fusion sockets in accordance with clause 6.2 of ISO 4427.
Mechanical fittings manufactured substantially from PE and intended for part fusion
to PE pipe and part mechanical jointing to other pipe components, e.g. adapters,
shall conform to the geometrical characteristics of the PE jointing system to be used.
Mechanical fittings not manufactured substantially from PE shall be in accordance
with ISO 14236 or other relevant standards, as applicable. Dimensions of loose
backing flanges and flange adapters shall be in accordance with ISO 9624. The test
pieces shall be tested in accordance with Table 4 of ISO 4427. When tested using
the test method and parameters specified therein, the fitting shall have mechanical
characteristics conforming to the requirements of Table 4 of ISO 4427. Mechanical
fittings shall be in accordance with ISO 14236.
CONNECTIONS:
Mark the welding area with a wax crayon or marker. Scrape the pipe surface carefully
using an approved scraper, after scraping; remove grease from the welding area of
the pipe and inside of the branch, using an approved cleaning agent.
Immediately after scraping and cleaning, apply the branch on to the pipe watching
out not to dirty the previously cleaned surfaces. Use a wrench to tighten the four
screw nuts until top and bottom part of branch saddle come into tight contact. Tighten
until the threaded connector A and the top part of branch saddle B meet, connect the
two electric pins to the welding connectors of the branch saddle. After completing the
welding process using Electro fusion method (using suitable electro-fusion
equipment), verify that no material has leaked out of the joint between the pipe and
the fitting and wait for cooling (20 minutes). Proceed now with the perforation of the
pipe. You can either leave the under clamp on the saddle or remove it as per the
instructions of engineer In Charge
SADDLE STRAP-FOR DI PIPES

Strap Saddle for service connection from water distribution mains shall be of wrap
around design, wide skirt and wide straps support, which shall reinforce the pipe
while providing excellent stability to the saddle. Saddles for service connections shall
be of fastened strap type with threaded outlet for service connection.
The service connection threading sizes shall conform to IS: 554. Saddles shall be
suitable for DI pipes of nominal size 4” (NB 100) with nominal service connection size
from ½” (NB 15). The straps shall be elastomeric coated (insulated) type for firm grip
on pipe as well as to protect the coating on the pipe and to insulate the un-identical
metals. Fasteners shall be of threaded nut-bolt-washer type. Nut-bolts of size ½”
(M12) shall be used for saddles of size for 4” (NB 100). The sealing between the
saddle and mains shall be obtained by using a profiled elastomeric seal matching to
the curvature of the pipe. The seal shall be of elastomeric type, suitable for all
potable water applications. The Material of construction of the body, straps, fasteners
etc. shall be of a non corrosive material such as engineering plastic (PE/PP) or
stainless steel or a combination of both. The design of the saddle body should be
such that, the service connection outlet metal insert shall project out towards pipe
side and align with the hole drilled on the pipe to ensure positive locking against
rocking or creeping on the pipe, as might be caused by vibration, pressure or
GWSSB 32
excessive external loading. The clamp saddles shall be suitable for maximum
working pressures upto 10 bars.
SADDLE BODY
Non corrosive Engineering Plastic body moulded with Stainless steel threaded metal
insert for tapping outlet. Also, the stirrup metal plate shall be duly embedded in the
plastic body, except at the place of nut-bolt lugs. Threading size and dimensions shall
conform to IS: 554. The body shall have retaining cavity housing for internal and
external retention of the elastomeric seal. Sealing shall be achieved by pressure
exerted by the body while fastening the saddle straps & body on the pipe.
SADDLE STRAP
Saddle straps shall be made of stainless steel 304 grade to prevent corrosion over
the long service life. Strap Insulation: Elastomeric (rubber) insulation / lining shall be
such that none of the Stainless Steel Strap is in direct contact with the pipe. It shall
ensure a firm non slip grip mounting on the pipe to prevent the saddle from rocking or
creeping on the pipe, as might be caused by vibration, pressure or excessive external
loading.
SADDLE SEAL
It shall be virgin rubber SBR Grade 30 / NBR (NSF 61 approved). It shall be of type
pressure activated hydro-mechanical design. It shall be contoured gasket to provide
a positive initial seal which increases with increase in the line pressure. Gasket shall
be gridded mat, with tapered ends, with the outlet section having oring contacting the
saddle body multiple o-rings contacting the pipe, preferably with a Stainless steel
reinforcing ring insert moulded to prevent expansion under pressure.
NUTS-BOLTS- WASHER
Stainless Steel Type 304, NC rolled thread, Tightening torque for ½” (M12) nut-bolt:
14-15 kg.m. The general arrangement of Strap Saddle with PP Compressive Male
Thread Metal Insert Elbow is shown below; The joints in service connection between
MDPE pipe and UPVC Ball Valve and the Water Meter shall be tamper proof / not
easily dismantled by the Consumers as directed by the Engineer.
FERRULE MATERIALS
Ferrule saddle straps shall be of gunmetal to BS EN 1982 grade (ISO R1338) or
equivalent, with two or four bolts depending upon the width of the saddle. Bolts shall
be of stainless steel to BS6105 grade A2 with grade A4 nuts, BS EN ISO 3506 and
be resistant to corrosion. The strap shall preferably be designed to have locating
recesses to prevent the bolt head(s) from turning when the upper nut is being
tightened. Ferrule outlets shall be either of a metallic material complying with the
specification for ferrule saddle straps above, or of a thermoplastics material that does
not suffer from corrosion in potable water (pH range 6 to 8) or low resistivity soils
(200 ohm.cm or less).Compression fittings for house service connections shall
comply with ISO 14236, with materials of construction as per clause 5 in the
Standard as follows:
GWSSB 33
Body - polypropylene
Nut/cap - polypropylene
Clip ring - POM (acetylic resin)
Packing bush - polypropylene
“O” ring - NBR
Threaded metal inserts - SS304 with BSP threads
For clear identification of water services, fitting nuts shall be coloured blue and the
body black. All threads shall be BSP. The dimensions of compression fittings shall be
in accordance with clause 7.1 of ISO 14236.The pressure rating of compression
fittings shall be PN 10 as per clause 8 of ISO 14236. Performance testing shall be as
follows:
Clause 8.2.1 Leak tightness under internal pressure
Clause 8.2.2 Resistance to pull-out
Clause 8.2.3 Leak tightness under internal vaccuum
Clause 8.2.4 Long term pressure test for leak tightness for assembled joint
Clause 8.3.2.1 MRS value as per ISO 9080
Clause 8.3.3.1 Resistance to internal pressure
All materials or components coming into contact with water shall comply with the
following:
Metallic components shall not constitute a toxic hazard, shall not support microbial
growth and shall not give rise to unpleasant taste or odours or discoloration.
Non-metallic components shall be approved as being free from adverse health
effects. Compliance with national or international standards shall be demonstrated by
production of appropriate third party certification.
Compression fittings for conveyance of water for human consumption shall conform
to BS 6920 for effects on water quality, and certificates demonstrating compliance
with the following parameters shall be provided: odour and flavour of water,
appearance of water, growth of micro-organisms, extraction of substances that may
be injurious to public health (cyto toxicity), and extraction of metals.
GWSSB 34
 DUCTILE IRON PIPES
Providing and supplying D. I. K-9 grade pipes with internal cement mortar
lining including GST, all taxes, insurance, transportation, freight charges,
octroi, inspection charges, loading, unloading, conveyance to departmental
stores, stacking etc. as directed by Engineer-in-charge.
I. Applicable Codes:
The manufacturing testing, supplying food grade pipes, at work sites of Ductile
Iron pipes shall comply with all currently applicable statutes, regulations,
standards and codes.
In particular, the following standards, specified herein shall be referred. In all

cases, the latest revision of the codes shall be referred to. If requirements of
specifications conflict with the requirements of the codes and standards, this
specification shall govern.
IS: 8329 Specification for Centrifugally Cast (spun) Ductile

Iron pressure pipes for water, gas and sewage
specification.
IS: 1387 General requirements for supply of metallurgical
materials.
IS: 1500 Methods for Brinell hardness test for metallic
materials.
IS:9523 Ductile Iron fittings for pressure pipes for water, gas
and sewage.
IS: 12820 Dimensional requirements. of rubber gaskets for
mechanical Joints and push on joints for use with
cast Iron pipes and fittings for carrying water, gas
and sewage.
ISO: 4179 Ductile iron pipes for pressure and no pressure-
Centrifugal cement mortar lining - General
requirements.
ISO: 2531 Ductile iron pipes, fitting and accessories for
pressure pipe lines.
IS: 12288 - Code of practice for use & laying of
Ductile iron pipes.
II. Manufacturing:
III. General
DI pipes shall be systematically checked for any manufacturing defects by
GWSSB 35
experienced supervisors and a very high standard quality shall be maintained.
 Owner / Engineer shall at all reasonable times have free access to the
place where the pipes are manufactured for the purpose of examining
and testing the pipes and for witnessing the test and manufacturing.
 All tests specified either in this specification or in the relevant Indian

Standards shall be performed by the supplier/contractor at his own
cost and in presence of Owner/Engineer if desired. For this, sufficient
notice before testing of the pipes shall be given to Owner/Engineer.
 If the test is found unsatisfactory, Owner/Engineer may reject any or

all pipes of that lot. The decision of Owner/Engineer in this matter shall
be final and binding of the contractor and not subject to any arbitration
or appeal.
IV. Materials
 The general requirements relating to the supply of material shall be as

per IS:1387.
V. Dimensions:
 The internal diameter, thickness and length of barrel, dimensions of

pipes shall be as per the relevant tables of IS.8329/IS: 9523 for
different class of pipes.
 The tolerances for pipes regarding dimensions and deviations from

straight line shall be as per relevant IS codes.
 The standard weight of uncoated pipes and the permissible tolerances

hall be per relevant IS codes.
VI. Workmanship and Finish
 The pipes shall be stripped, with all precautions necessary to avoid

warping or shrinking defects. The pipes shall be free from defects,
other than any unavoidable surface imperfections which result from
the method of manufacture and which do not affect the use of the
pipes in the opinion of Engineer.
 The pipes shall be such that they could be cut, drilled or machined.
The hardness of the external unmachined surface shall not exceed
230 HBS.
 In the case of spigot and socket pipes and fittings for lead joints, the
socket shall be without the centering ring.
GWSSB 36
 In the case of flanged pipes the flanges shall be at the right angles to
the axis of the pipe and machined on face. The bolt holes shall be
drilled and located symmetrically off the center line. The bolt hole
circle shall be eccentric with the bore and bolt holes equally spaced.
The flanges shall be integrally cast with the pipes and fittings and the
two flanges of the pipes shall he correctly aligned.
VII. Testing
 Mechanical Tests:
Mechanical tests shall be carried out during manufacture of pipes as

specified in relevant IS codes. The results so obtained shall be
considered to represent all the pipes and fittings of different sizes
manufactured during that period and the same shall be submitted to
Owner/Engineer. The method for tensile tests and the minimum
tensile strength requirement for pipes shall be as per relevant IS
codes.
 Brinell Hardness Test
For checking the Brinell hardness, the test shall be carried out on the
test ring or bars cut from the pipes used for the ring test and tensile
test in accordance with IS 1500.
 Retests
If any test piece representing a lot fails in the first instance, two
additional tests shall be made on test pieces selected from two other
pipes from the same lot. If both the test results satisfy the specified
requirements, the lot shall be accepted. Should either of these
additional test pieces fail to pass the test, the lot shall be liable for
rejection.
 Hydrostatic Test
For hydrostatic test at works, the pipes shall be kept under test
pressure as specified in relevant IS codes for 15 seconds, shall be
struck moderately with a 700 g hammer for confirmation of
satisfactory sound. They shall withstand the pressure test without
GWSSB 37
showing any leakage sweating, or other defect of any kind. The

hydrostatic test shall be conducted before coating the pipes.
VIII. Coating
 All D.I. pipes shall be delivered with internal lining and external coating.
 Coating shall not be applied to any pipe unless its surface is clean dry
and free from rust.
 All DI pipes shall be mortar lined on internal surface as specified in

ISO: 4179 and externally coated with bituminous paint as specified in
IS: 8329.
IX. Marking
 Each pipe shall have cast stamped or legibly and indelibly painted on it
with the following appropriate marks:
a) The nominal diameter.
b) Class reference.
c) Mass of pipe.
d) Date of' manufacture and
e) Manufacturer's name, initials or identification mark.
 Marking shall be done as per IS: 8329.
X. Transporting of Pipes
All pipes manufactured in the factory and temporarily stacked in the Contractor's
yard shall be transported to the site of laying after cleaning them internally etc.
The item of transport covers the cost of loading in the factory, transporting to the
site of laying or to stacking yard selected by the Engineer in its vicinity and
unloading and stacking them carefully in such a manner that the material so kept
is not easily disturbed or rolled away from the place of stacking. The loading in
the factory shall be carried out by means of either a crane, gantry or shear legs,
so as not to cause any damage to the finished material. Similarly, while unloading
and stacking, great care shall be taken to ensure that the material is not
damaged or dented. The contrivances to be used for unloading will be different in
different situations and in each case the one approved by the Engineer shall be
adopted. The material stacked at site shall be jointly inspected by the Engineer
and the Contractor and defect or damage noticed shall be repaired to the
satisfaction of the Engineer before payment is admitted.
GWSSB 38
The stacking ground, both in the Contractor's yard and at the site of
laying shall be selected in such a way as not to get waterlogged during
monsoon. If this cannot be done, the pipes shall be supported on
sleepers to avoid contact with wet earth.
As explained in earlier paragraphs, materials such as pipes, tapers,

etc. may be transported to the site of laying as soon as the material is
finished in all respects with the permission of the Engineer.
XI. Procedure for Receiving DI Pipes:
 Handling of Pipes,
It is essential to avoid damage to the pipes, or their coatings at all

stages during handling. The pipes shall be handled in such a manner
as not to distort their circularity or cause any damage to their surface
treatment. Pipes shall not be thrown down from the trucks nor shall
they be dragged or rolled along hard surfaces. Slings of canvas or
equally non-abrasive materials of suitable width of special attachment
shaped to fit the pipe ends shall be used to lift and lower coated pipes
to prevent damage to the coating.
Great care shall be taken in handling the pipe right from the first
operation of manufacture until they are delivered to the store. No
defective or damaged pipe shall be allowed in the work without
rectification/replacement to the satisfaction of the Engineer. Any
damage to the coating shall be repaired by the Contractor at his own
cost to the satisfaction of the Engineer.
XII. Laying of Ductile Iron Pipes and Fittings / Specials
 Scope
The specification covers laying of DI pipes and DI fittings/specials for

overground/underground works.
 Applicable codes
The laying of pipes and fittings/specials shall comply with all currently applicable
status, regulation, standards and codes. In particular, the following standards,
unless otherwise specified herein, shall be referred to. In all cases, the latest
revision of the standards/codes shall be referred to. If requirements of this
specification conflict with the requirements of' the standards/codes, this
 Codes of practice
IS:8329 Centrifugally cast (spun) Ductile Iron pressure pipe for water, gas
and Sewage.
IS:3764 Excavation Work - Code of Safety.
GWSSB 39
IS:12288 Code of Practice for use and laying of Ductile iron pipes.
 Carting & handling
Pipes and fittings/specials shall be transported from the factory to the work sites
at places along the alignment of pipeline as directed by Owner/Engineer and as
specified by manufacturer. Contractor shall be responsible for the safety of pipes
and fittings/specials in transit, loading/unloading. Every care shall be exercised in
handling pipes and fittings/specials to avoid damage. While unloading, the pipes
and fittings/specials shall not be thrown down from the truck on to hard surfaces.
They should be unloaded on timber skids with steadying ropes for by any other
approved means. Padding shall be provided between coated pipes,
fittings/specials and timber skids to avoid damage to the coating. Suitable gaps
between pipes should be left at intervals in order to permit access from one side
to the other. in case of spigot socket pipes, care should be taken regarding
orientation of pipes while unloading. As far as possible pipes shall be unloaded
on one side of the trench only. All pipes shall be checked for any visible damage
(such as broken edges, cracking or spalling of pipe) while unloading and shall be
sorted out for recantation. Any pipe which shows sufficient damage to preclude it
from being used shall be discarded. Dragging of pipes and fitting/specials along
concrete and similar pavement with hard surfaces shall be prohibited.
 Storage
Each stack of pipes shall contain only pipes of same class and size, with
consignment or batch number marked on it with particulars of suppliers wherever
possible. Storage shall be done on firm level and clean ground and wedges shall
be provided at the bottom layer to keep the stack stable. The stack shall be in
pyramid shape or the pipes laid lengthwise and crosswise in alternate layers.
The pyramid stack shall be made for smaller diameter pipes for conserving
space in storing them. The height of the stock shall not exceed 1.5m.
Fittings/specials, shall be stacked under cover and separated from pipes.
Rubber rings shall be stored in a clean, cool store away from windows, boiler,
electrical equipment and petrol, oils or other chemicals. Particularly in the field
where the rubber rings are being used it is desirable that they are not left out on
the ground in the sun or overnight under heavy frost or snow conditions.3
 Laying
o Excavation
Before excavating trench the alignment of pipeline shall be approved by

Engineer. The excavation shall be carried out in accordance with the
specifications mentioned under Section 4, Parts 1 and shall be done such that it
does not get far ahead of laying operations.
GWSSB 40
To protect persons from injury and to avoid damage to property, adequate

barricades, construction signs, red lanterns and guards as required shall be
placed and maintained during the progress of the construction work and until it is
safe for the traffic to use the roadways. The relevant Indian standards and the
rules and regulations of local authorities in regards to safety provisions shall be
observed.
Suitable fencing shall be provided along the sides of trenches and pits. The
posts of fencing shall be of timber securely fixed in the ground not more than 3 in
apart and they shall not be less than 75 mm in diameter or less than 1.2 m above
surface of the ground. There shall be two rails, one near the top of the post and
the other about 450 mm above the ground and each shall be from 50 mm to 70
mm in diameter and sufficiently long to run from post to post to which they shall
be bound with strong rope. The method of projecting rails beyond the post and
tying them together where they meet will not be allowed on any account. All
along the edges of the excavation trenches a bank of earth about 1.2m high shall
be formed where required by Owner/Engineer for further protection.
The road metal and also the rubble packing shall first be stripped off for the
whole width of the trench/pit and separately deposited in such place or places as
may he determined by Owner/Engineer.
During excavation, large stones and rubble shall be separated and removed from
the excavated soil and stacked separately. The material from excavation shall be
deposited on either side of the trench leaving adequate clear distance from the
edges of the trench and pit, or as may be necessary to prevent the sides of the
trench pit to slip or fall, or at such a distance and in such a manner as to avoid
covering fire hydrants, sluice valves, manholes covers etc. and so as to avoid
abutting the wall or structure or causing inconvenience to the public and other
service organisations or otherwise as Owner/Engineer may direct.
Contractor shall take into account additional excavation if any as

Owner/Engineer may require in order to locate the position of water pipes,
drains, sewers etc. or any other works which may be met with, in or about the
excavation of trenches/pits while quoting the rates for excavation of trenches/pits
while quoting the rates for excavation. Such service lines if met with during
excavation shall be properly maintained by Contractor, by means of shoring,
strutting, planking over, padding or otherwise as Owner/Engineer may direct, and
shall be protected by the Contractor from damage during the progress of the
work. All precautions shall be taken during excavation and laying operations to
guard against possible damage to any existing structure/pipe line of water, gas,
sewage etc.
If the work for which the excavation has been made is not completed by the
expected date of the setting of monsoon or the setting in of rain whichever is
earlier, or before the day fixed by Owner/Engineer for filling in any excavation on
account of any festival or special occasion, Contractor shall backfill such
excavation and consolidate the filling.
GWSSB 41
Utmost care shall be taken to see that the width of the trench upto ground level is
not more than that specified in 'Data sheet – B’. If any extra width is provided in
the pipezone, the Contractor shall have to provide remedial measures in the form
of lime concrete or rubble masonry otherwise at the discretion and to the
satisfaction of Owner/Engineer. If rock is met with, it shall be removed to 15 cm
below the bottom of pipes and fittings/specials and the space resulting shall be
refilled with granular materials and properly consolidated. Bottom of trenches/pits
shall be saturated with water well rammed wherever Owner/Engineer may
consider if necessary to do so.
Wherever a socket or collar of pipe or fitting/special occurs, a grip is to be cut in

the bottom of the trench or concrete bed to a depth of at least 75 mm below the
bed of the pipe so that the pipe may have a fair bearing on its shaft and does
not rest upon its socket. Such grip shall be of sufficient size in every respect to
admit the hand all around the socket in order to make the joint, and the grip shall
be maintained clear until the joint has been approved by Owner/Engineer.
When welding is to be carried out with the pipes and specials in the trench,
additional excavation of not more than 60 cm in depth and 90 cm in length shal1
be made at joints in order to facilitate welding.
The excess excavated material shall be carried away from site of works to a
place upto a distance as directed by Owner/Engineer. This shall be done
immediately so as not to cause any inconvenience to the public or traffic. If the
instructions from Engineer are not implemented within seven days from the date
of instructions to cart the materials and to clear the site, the same shall be
carried out by Owner/Engineer and any claim or dispute shall not be entertained
in this respect.
The contractor shall make proper provision for protecting the work by fencing,
watch and ward lighting at right on in an other manner as may be directed by
Engineer.
o De-watering
During the excavation, if subsoil water is met with Contractor shall have to
provide necessary equipment and laborers for dewatering the trenches/pits by
bailing out water or water mixed with clay if pumping out subsoil water is found to
be necessary, Contractor shall provide sufficient number of pumps for the same.
In both the above cases the excavation shall be done to the required level and
the pipes shall be laid to proper alignment and gradient. Contractor shall also
make necessary arrangement for the disposal of drained water to nearby storm
water drain or in a pit if allowed by Owner/Engineer. In no case the water shall
be allowed to spread over the adjoining area. Before discharging this water into
public sewer/drain, Contractor shall take necessary permission from the local
authorities.
o Special foundation in poor soil
GWSSB 42
Where the bottom of the trench and subgrade is found to consist of material
which is unstable to such a degree that in the opinion of Owner/Engineer, it
cannot be removed and replaced with an approved material thoroughly
compacted in place to support the pipe properly, a suitable foundation for the
pipes, consisting of piling, limbers or other materials, in accordance with relevant
drawings and as instructed by Owner/Engineer shall be constructed.
o Wooden shoring
Contractor shall suitably design polling bards, waling and struts to meet different
soil conditions that might be encountered in excavating trenches/pits. The
horizontal and vertical spacing of struts shall be prevented from collapse but also
easy lowering of pipe in trenches shall be ensured without creating undue
obstructions for the excavation of the work. Any inconvenience and/or delay that
might be caused in lowering pipes in trenches as a result of adopting improper
spacing of struts by Constructor shall be his sole responsibility. No part of
shoring shall at any time be removed by Contractor without obtaining permission
from Owner/Engineer. While taking out shoring planks the hollows of any form
must simultaneously be filled in with soft earth well rammed with rammers and
with water.
Owner/Engineer may order portions of shoring to be left in the trenches/pits at

such places, where it is found absolutely necessary to do so avoid any damage
which may be caused to buildings, cables, gas mains, water mains, sewers etc.
in close proximity of the excavation, by pulling out the shoring from the
excavations. Contractor shall not claim, on any reason whatsoever, for the
shoring which may have been left in by him at his own discretion.
o Steel plate shoring
Where the subsoil conditions are expected to be of a soft and unstable character
in trench/pit excavation, the normal method of timbering may prove insufficient to
avoid subsidence of the adjoining road surface and other services. In such
circumstances Contractor will be required to use steel trench sheeting or sheet
piling adequately supported by timber struts, waling etc. as per the instructions
manner and method directed by Owner/Engineer. Contractor shall supply, pitch,
drive and subsequently remove trench sheeting or piling in accordance with
other items of the specification.
o Boning staves and sight rails
In laying the pipes and fittings/specials the centre for each manhole/chamber or
pipeline shall be marked by a peg. Contractor shall dig holes for and set up two
posts (about 100 x 100 x 1800 mm) at each manhole chamber or junction of
pipelines at nearly equal distance from the peg and at sufficient distances
GWSSB 43
therefrom to be well clear of all intended excavation, so arranged that a sight rail
when fixed at a certain level against the post shall cross the centre line of the
manhole/chamber or pipe lines. The sight rail shall not in any case be more
than 30 m apart, intermediate rails shall be put up if directed by Owner/Engineer.
Boning staves of 75 mm x 50 mm size shall be prepared by Contractor in

various lengths, each length being of a certain whole number of metres and with
a fixed tee head and fixed intermediate cross pieces, each about 300 mm long.
The top-edge of the cross piece must be fixed below the top edge of the tee-
head at a distance equal to the outside diameter of the pipe of' the thickness of
the concrete bed to be laid as the case may be. The top of cross pieces shall
indicate different levels such as excavation for pipe line, top of concrete bed, top
of pipe etc. as the case may be.
The sight rail of size 250 mm x 40 mm shall be screwed with the top edge
resting against the level marks. The centre line of the pipe shall be marked on
the rail and this mark shall denote also the meeting point of the centre lines of
nay converging pipes. A line drawn form the tip edge of one rail to the top edge
of the next rail shall be vertically parallel with the bed of the pipe, and the depth
of the tee letting down the selected boning staff until the tee head comes in the
line of sight from rail to rail.
The post and rails shall be perfectly square and planed smooth on all sides and
edges. The rails shall be painted white on both sides, and the tee-heads and
cross-piece of the boning staves shall be painted black.
For the pipes converging to a manhole chamber at various levels, there shall be
a rail fixed every different level. When a rail comes within 0.60 m of the surface
of the ground, a higher sight-rail shall be fixed for use with the rail over the next
point.
The posts and rails shall in no case be removed until the trench is excavated,
the pipes the laid Owner/Engineer gives permission to proceed with the
backfilling.
o Bedding
The type of bedding for pipes shall be as per Data Sheet - B.
DATA SHEET – B
Sr. No. Item No. Specification
1 Width of trench
OD – Outer Diameter of pipeline in m OD + 0.9 m
2 Bedding for pipes As per drawing
GWSSB 44
 Laying of Pipes and Fittings/Specials
All precautions shall be taken during excavation and laying operations to guard
against possible damage to any existing structure/pipeline of water, gas, sewage
etc. After excavation of trenches, pipes shall not be lowered unless the
dimensions of trenches and bedding work for pipes at the bottom of the trenches
are approved and measured by Owner/Engineer. Pipes and fittings/specials
shall be carefully lowered in the trenches. Special arrangements such as cranes,
tripods with chain pulley block for lowering the pipes and fittings/specials shall
be made by Contractor. In no case pipes and fittings/specials shall be dropped.
Slings of canvas or equally non-abrasive material of suitable width or special
attachment to fit the ends of pipes and fittings/specials shall be used to lift and
lower the coated pipes and fittings/specials. The pipes and fittings/specials shall
be inspected for defects and be rung with a light hammer preferably while
suspended to detect cracks. If doubt persists, further confirmation shall be done
by pouring a little kerosene/dye on the inside of the pipe at the suspected spot.
No sign of kerosene/dye should appear on the outside surface. Pipes and
fittings/specials damaged during lowering or aligning shall be rejected by
Owner/Engineer. Manufacturers recommendations are to be followed for laying
pipes.
All the pipes are to be laid perfectly true both in alignment and to gradient
specified. In case of spigot and socket pipe the socket end of the pipe shall face
upstream, except when the pipeline runs uphill in which case the socket ends
should face the upgrade. The laying of pipes shall always proceed upgrade of a
slope. After placing a pipe in the trench, the spigot end shall be centered in the
socket and the pipe forced home and aligned to required gradient. The pipes
shall be secured in place with approved backfill material tamped under it except
at the socket. pipes and fittings/ specials which do not allow a sufficient and
uniform space for joints shall be removed and replaced with pipes and
fittings/specials of proper dimensions to ensure such uniform space.
Precautions shall be taken to prevent dirt from entering the jointing space. At
times when pipe laying is not in progress, the open ends of pipe shall be closed
by a watertight plug or other means approved by Owner/Engineer. During the
period that the plug is on, the Contractor shall take proper precautions against
floating of the pipe owing to entry of water into the trench. Wherever it is
necessary to deflect pipe from a straight line, either in the vertical or horizontal
plane, to avoid obstructions or where long radius curves are permitted the
deflection allowed at joints shall not exceed 2 1/2o. In case of pipes, with joint to
be made with loose collars, the collars shall be slipped on better the next pipe is
laid. The pipes shall be laid such that the marking on pipes appears at the top of
the pipes.
The cutting of pipe for inserting valves, fittings or specials shall be done in a neat
and workman like manner by using tools and taking precautions as per
manufacturers’' recommendations without damage to the pipe so as to leave a
GWSSB 45
smooth end at right angles to the axis of the pipe. For this purpose, pipe cutting
machine shall be used.
 Repairs of Damaged Cement Mortar Linings
The mortar lining is strongly bonded with the pipe wall at all places. However,
near the spigot end due to rough handling of pipes or on account of incidental
shock loads the mortar lining may get damaged over a small area. Such
damages if taken place shall be immediately identified and repaired before
installation. When repairing damaged cement-mortar-lining, the following shall
be adhered to:
o Materials required
(a) Standard Cement (of the same quality as in the lining)
(b) Argillaceous Sand (size of coarse grains max. 1.6 mm)
(c) Acrylic Emulsion for cement mortar
(d) Potable water
o Preparation of the areas to be repaired
The damaged lining shall be removed with hammer and chisel, with due care
without disturbing the surrounding lining. Contractor shall supply protective
spectacles for workmen to prevent penetration of cement fragments into their
eyes.
o Composition of repair mortar
The proportion of the materials will be as follows:
o Dry mixture of mortar:
One part of cement
One part of sand
o Emulsions:
One part of acrylic emulsion
GWSSB 46
Four parts of potable water
Firstly the dry sand and the dry cement shall be mixed separately. The acrylic
emulsion shall be added to the water stirring constantly (The container for
acrylic emulsion should be resealed at once after use and stored in a cool
place)Small quantities of the treated water shall be gradually added to the
cement and sand mixture mixed thoroughly. Care shall be taken not to
prepare too large quantity of cement to avoid premature hardening.
Any loose sand from the areas to be repaired shall be brushed off. Moisten
the areas under repair and surrounding areas with water but avoid water
accumulations. Mortar is to be applied to cleaned areas and the lining surface
is to be smoothened.
o After - Treatment of repaired areas
In order to ensure faultless hardening of cement it is recommended that the

repaired area to be covered temporarily with plastic sheet. In the case of
diameters exceeding DN 300 it is possible that after cutting off a piece the
new spigot end has become out of round. On account of the elastic and
plastic properties of ductile iron, it is possible to re-round these pipe ends.
This shall be done on site by means of a hydraulic or mechanical jack, acting
from inside and pressing outwards or by using a press acting from outside
the pipe and pressing inwards by the contractor.
In order to avoid damage to the cement mortar lining it is recommended that

hardwood ads of a shape to match the pipes internal diameter be used. The
re-rounding device should remain in place during assembly. If necessary
the manufacture may consulted for resounding.
 Thrust Blocks
Thrust blocks shall be provided, to counteract hydraulic thrust, at requisite

places as per design as directed by Engineer In-charge.
 Jointing
Jointing for pipes and fittings/specials shall be done in accordance with the
relevant specifications for DI pipes and DI fittings and as recommended by
manufacturer.
The recommended bolting torque to be followed for assembling flanges as

specified in manufacturer instructions.
 Testing And Commissioning
Testing and commissioning of pipes shall be done in accordance with the

relevant specification.
GWSSB 47
 Backfilling
Trenches shall he backfilled with approved selected excavated material only

after the successful testing of the pipeline as directed by engineer. The tamping
around the pipe shall be done by hand or other hand-operated mechanical
means. The water content of the soil shall be as near the optimum moisture
content as possible. Filling of the trench shall be carried out simultaneously on
both side of the pipe in such a manner that unequal pressure does not occur.
Backfilling shall be done in layers not exceeding 30 cm. Each layer shall be
consolidated by watering, ramming, care being taken to avoid damage to the
pipeline. Where timbers are placed under the pipeline to aid alignment, these
timbers shall be removed before backfilling.
 Reinstatement Of Road/Footpath
Reinstatement of road/footpath shall be done as per the requirements of local

authorities and the relevant specifications after completion of work.
 Clearing Of Site
All surplus materials, and all tools and temporary structures shall be removed
from the site as directed by Owner/Engineer and the construction site left clean
to the satisfaction of Owner/Engineer.
 Cleaning, Disinfectioning And Commissioning Of The Pipeline
Upon completion of newly laid main, the main shall be disinfected as directed by
the Engineer.
The main shall be flushed prior to disinfection except when the tablet method is
used. After initial flushing, the hypochlorite solution shall be applied to the water
main with mechanically or electrically powered chemical feed pump designed for
feeding chlorine solutions. For small applications, the solution may be fed with a
hand pump.
In the case of main of large diameter, water from the existing distribution system
or other approved source of supply shall be made to flow at a constant
measured rate into the newly laid pipeline. The water shall receive a dose of
chlorine also fed at constant measured rate. The two rates shall be proportioned
so that the concentration in the water entering the pipeline is maintained at no
less than 300 mg/l. The chlorine shall be applied continuously and for a sufficient
period to develop a solid column of ‘slug’ of chlorinated water that will as it
passes along the line expose all interior surfaces to a concentration of at least
300 mg/l for atleast 3 hours. As the chlorinated water flows past tees and
crosses related valves and hydrants shall be operated so as to disinfect the
appurtenances.
GWSSB 48
In the case of newly laid mains in which scrupulous cleanliness has been
exercised the tablet method can be adopted and in this method, the initial
flushing is dispensed with. The calcium hypochlorite tablets are placed in each
section of pipe and also in hydrants, hydrant branches and other appurtenances.
The tablets shall be attached by an adhesive and must be at the top of the
main. The main shall then be filled with water and the water shall remain in the
pipe for atleast 24 hours.
After the applicable retention period, the heavily chlorinated water shall be
flushed from the main until the chlorine concentration in the water leaving the
mains is not higher than that generally prevailing in the system or less than 1
mg/l.
After final flushing and before the water main is placed in service, a sample (s)
of water shall be collected from the end of the line and tested for bacteriological
quality and shall show the absence of coliform organisms. If the initial
disinfection fails to produce satisfactory samples, disinfection shall be repeated
until satisfactory, samples are obtained before the main is placed in service.
The Contractor is expected to carry out the disinfection work as a part of laying
the pipes and his rates for laying the pipes should include the disinfection and
other connected works till the main is placed in service, unless otherwise
specified in the schedule.
 Method of Measurement
The measurement shall be recorded in running meter of pipe length laid along
the centerline of axis of pipeline including specials surcharge tee, enlarge,
reducer and bend, correct up to 0.01 m length.
 Payment
GWSSB 49
 MS PIPELINES, APPURTENANCES SPECIALS ETC.
SCOPE
This specification covers the general requirements for supply, fabrication, delivery at site
laying, jointing, testing and commissioning of all welded M.S pipeline, appurtenances,
specials etc. above/below ground, including Civil works required for the same.
APPLICABLE CODES & SPECIFICATIONS
The following specifications, standards and codes are made a part of the specification. All
standards, tentative specifications, specifications, codes of practice referred to herein
shall be the latest editions including all applicable official amendments and revisions.
In case of discrepancy between this specification and those referred to herein, this
1. IS: 2062 Steel for general structural purposes.

2. IS : 808 Dimensions for hot rolled steel beam, column, channel and angle
sections.
3. IS : 814 Covered Electrodes for manual Metal Arc Welding of carbon and
C-Mn steel.
4. BS EN 499 Welding Consumables. Covered Electrodes for Manual Metal Arc

Welding of Non Alloy and Fine Grain Steel. Classification
5. AWS: A-5.1 Specification for Mild Steel Covered Arc Welding Electrodes.
6. IS : 3613 Acceptance Tests for Wire Flux combinations for Submerged - Arc
Welding.
7. AWS: A-5.17 Specification for Bare Mild Steel Electrodes and Fluxes for
Submerged Arc Welding
8. IS: 1367 Technical Supply Conditions for Threaded Fasteners (Parts 1 to 3).
9. IS: 2016 Plain Washers.
10. IS: 2074 Ready Mixed Paint, Red Oxide Zinc Chrome and Priming.
11. IS: 102 Ready Mixed Paint, Brushing, Red Lead, no setting, Priming.
12. IS: 1786 High Strength Deformed Steel Bars and Wires for Concrete
Reinforcement
13. IS : 432 Specification for Mild Steel & (Part-I) Medium Tensile bars and hard
drawn steel wire for concrete reinforcement : mild Steel & Medium
tensile steel bars.
14. IS.432 Specification for mild steel & (Part-II) Medium Tensile steel bars
and harddrawn steel wires for concrete reinforcement : Hard drawn
GWSSB 50
steel wire
15. IS : 269 Specification for Ordinary and Low heat Portland cement
16. IS : 8041 Specification for Rapid hardening Portland Cement
17. IS : 383 Specification for coarse and fine aggregate from natural source for
concrete
18. IS :12330 Specification for Sulphate Resisting Portland Cement

19. IS : 456 Code of practice for plain and reinforced concrete
20. IS : 800 Code of practice for General Construction in Steel.
21. IS : 816 Code of practice for use of Metal Arc Welding for General
Construction in mild steel.
22. IS : 4353 Submerged Arc Welding of Mild Steel & Low Alloy Steels –
Recommendations.
23. IS: 817 Code of practice for Training and Testing of Metal Arc Welders.
24. IS: 1182 Recommended practice for Radiographic examination of Fusion - Welded
Butt Joints in steel plants
25. IS: 2595 Code of Practice for Radiographic Testing.

26. IS: 3658 Code of Practice for Liquid Penetrate Flaw Detection
27. IS: 5334 Code of practice for Magnetic Particle Flaw Detection of welds.
28. ASTM E 94 Guide for Radiographic Testing
29. ASTM E 709 Guides for Magnetic Particle Examination.
30. ASTM E 165 Test Method for Liquid Penetrate Examination.
31. IS: 3600 Methods of Testing Fusion Welded Joints and weld metal in steel (Parts
1 to 9)
32. IS: 4853 Recommended Practice for Radiographic Inspection of Fusion Welded
Butt Joints in Steel Pipes.
33. IS: 1239 Seamless or Electrically welded steel pipes for Water Gas and Sewage
(Up to 166.5 mm Outside Diameter)
34. IS: 3589 Seamless or Electrically welded steel pipes for Water Gas and Sewage
(168.3 to 2540 Outside Diameter)
35. IS: 6631 Steel pipes for Hydraulic Purposes
36. IS: 7343 Code of practice for ultrasonic Testing of Ferrous Welded Pipes and
Tubular Products
37. IS: 2598 Safety Code for Industrial Radiographic Practice
38. IS: 5822 Code of Practice for Laying of Electrically Welded steel pipes for water
supply
39. IS: 1608 Mechanical testing of Metals.
40. IS: 9595 Metal Arc welding of Carbon and Carbon-Manganese Steels.
41. IS: 2825 Code of unfired Pressure Vessels
42. IS:5504 Code for Spiral Welded PIPES(457mm to 3250mm Outside Diameter)
43. IS: 10748 Requirements for Wieldable Hot Rolled Carbon Steel Strip in Coils.
44. IS: 10234 Recommendation for radiography for general pipeline welding.
45. API-1104 Welding of pipeline & related facilities
MATERIALS
1..1 Steel Coils - The steel Coils for pipes, fittings, specials and stiffeners shall be of
mild steel conforming to IS: 10748 grade III and shall bear ISI mark
GWSSB 51
1..2 Welding Consumables - such as electrodes, filler rods and wires shall conform to
IS: 814, IS: 3613, IS: 6419 and IS: 7280 and shall be of GWSSB approved make.
Before fabrication of pipes and specials/fittings is commenced, the copies of the

mill sheets and the manufacturer's test certificates for Coils and other materials
required for the fabrication shall be submitted by the Contractor to the Engineer
for his approval.
When requested by the Engineer, the Contractor shall supply free of charge to
the Employer, for testing suitable samples of the materials to be used/used in the
Works. The cost of such tests shall be borne by the Contractor and shall be
included in his item rates.
INSPECTION
1..3 All works and material under specification will be rigidly inspected during all
phases of manufacture and testing and such inspection shall not relieve the
Contractor of his responsibility to furnish materials and performed work in
accordance with this specification.
1..4 The Contractor shall notify the Engineer, in advance of the production of
materials and fabrication thereof, in order that the Employer may arrange for mill
and shop inspection.
1..5 The Engineer may reject any or all materials or works that do not meet with any
of the requirements of this specification. The Contractor shall rectify or replace
such rejected material/performed work at his own cost, to the satisfaction of the
Engineer.
1..6 The Engineer shall have free access to those parts of all plants or any other
premises and sites that are concerned with the furnishing of materials or the
performance of work under this specification.
1..7 The Contractor shall furnish to the Employer's inspector reasonable facilities and
space without charge for inspection, testing and obtaining of any information he
desires in respect of the character of material used and the progress and manner
of the work.
1..8 The Contractor shall supply free of cost required specimen of materials for testing
by the Owner at any time during the progress of work and shall bear the cost of
all such tests or retests to the satisfaction of Engineer.
1..9 The Contractor shall provide 2 (two) sets of accurate `Go' and `No Go' ring
gauges to measure the diameter of pipes specials and fitting for the use of the
Engineer at no extra cost.
GWSSB 52
FABRICATION OF PIPE
1.5.1 GENERAL
1..9.1 All pipes and specials shall be manufactured as per IS: 1239 part 1/ IS: 3589
and IS: 5504out of new mild steel HR Coils (IS: 10748 grade-III) which shall be
free from any cracks, surface flaws, laminations, excessive fittings or any other
defects. The pipes shall be truly cylindrical, and straight in axis. The ends shall be
accurately cut and prepared for field welding. The external circumference of the
pipe pieces which are to be fixed adjacent to flange adapter with fixed outer
diameter shall not deviate from theoretical one by more than 1 mm. To obtain this
accuracy the pipe shall be rolled several times, if necessary, as pipe pieces should
be truly cylindrical. The external longitudinal welding of this pipe shall be ground
smooth flush with surface to the satisfaction of the Engineer, for a length of 200
mm. No extra cost shall be charged by the Contractor for this grinding work.
However, the pipe shall be manufactured as per tender specification.
1..9.2 Minor repair by welding or otherwise shall be permitted at the discretion of the
Engineer, but such repairs shall be done only after obtaining the previous
permission of the Engineer. Any pipe or part thereof which develops injurious
defects during shop welding or other operations shall be rejected.
1..9.3 Permissible Stress

The permissible stress in the pipe shell shall be related to yield stress (f y) of pipe
material making due allowance for weld efficiency of the joint.
i) working stress for combined bending and direct tensile stress shall not
exceed 60% of yield stress of the material making due allowance for
efficiency of welded joint (as per IWWA M-1).
ii) Working stress for combined bending and direct compressive stress shall not
exceed 50% of yield stress making due allowance for weld efficiency (as per
IWWA M-1).
iii) It is also necessary to check the shell thickness for adequate factor of safety
against failure by buckling (as per IWWA M-11).
For field welded joint, efficiency factor of 80% is generally adopted, while for
shop welding joint 90% efficiency is allowed (as per IS 5822 ).
1..10 FABRICATION
1..10.1 The Contractor shall get the fabrication work done in a duly valid licensed factory
of his own or that of an approved nominated sub-contractor. This factory meant
for fabrication of pipes, specials etc. shall also be involved with testing etc.,
machining as well as painting. For completing the work under the present
contract within the contract period, the factory shall be equipped with adequate
number of various equipment and plant such as :
i) Plate bending machines for rolling of pipe drums
ii) Automatic welding machines (suitable for circumferential welding)
iii) Hydraulic Testing Machines
iv) Travelling gantry or crane of capacity 10 Tones or above.
GWSSB 53
v) Mobile cranes for loading/unloading of Coils, pipes etc. 15 tones capacity

each
vi) Lathe for machining of the flanges rings, Coils etc.
vii) Equipment for sand blasting and applying paint by spray gun.
viii) Equipment for cold pressing of Coils up to 25 mm thick to the required
curvature (specials, plug Coils etc.)
ix) Bending machine of adequate capacity for manufacturing ring girders and
other necessary equipments.
1..10.2 The factory shall have adequate area, and shall also have stacking yard for the
stacking of Coils, structural, fabricated pipes etc. and the scrap.
1..10.3 The Bidder may establish pipe fabrication factory within the project site for
minimizing the transportation of pipes after fabrication to bring the pipes to the
trench where pipes are to be laid. Contractor shall furnish with his bid the details
of the factory where he intends to get the fabrication done, such as its location
within the project site and the equipment, plant and other facilities available in the
factory for the manufacture of M.S. Pipes and special required under this
contract.This shall be as per the MOU executed with the pipe manufacturer.
1..11 CUTTING OF COILS or FROM COIL ROLLED AS PER REQUIRED SIZES
1..11.1 The Coils shall be indented in such length as to have minimum wastage and so
as to make the pipe as far as possible.
1..11.2 Before cutting, all the edges of the Coils shall be cleaned by brushing/grinding on
both the sides.
1..11.3 After the Coils are cut, the edges shall be made smooth and even by polishing
with an electrical or pneumatic grinder to remove all inequalities. Care shall be
taken to see that the cut edges of the plate are perfectly straight. Jigs to be used
for this purpose shall depend upon the types of cutting machine used. The Coils
cut to the required shape shall be checked for correctness before they are rolled
into pipe drums. If any corrections are required, the Contractor shall do the same
by re-cutting, if necessary.
1..11.4 Rolling of Coils
1..11.5 The Coils prepared as mentioned above are cut to the exact size shall be put into
a rolling machine to form a pipe of the required diameter as under :
 The Contractor shall adjust the rolling machine so as to give a uniform
curvature to the pipe throughout its circumference.
 The curvature obtained shall be checked by the Contractor's foreman during
the process of rolling and if proper curvature is not obtained at any place
including the ends, the rolling operation shall be repeated at this stage
 Heating of Coils to obtain the desired curvature shall not be permitted.
GWSSB 54
1..12 WELDING
1..12.1 All components of a standard shell, either straight or bent etc. shall be welded,
wherever possible by use of automatic arc welding machine by Submerged Arc
Welding Process with alternating current. Generally hand welding shall not be
permitted except specific cases, where it is absolutely necessary. This should be
done in consent with client’s representative. Hand welding shall also not be
permitted except for sealing runs and such other minor works at the discretion of
the Engineer-in-charge. The strength of the joint shall be at least equal to that of
the parent material.
1..12.2 The Contractor shall use electrodes of GWSSBapproved make and size, the size
depending on the thickness of coil and the type of joint. It shall also be used with
standard current and arc voltage required for the machine in use with such
modifications as may be found necessary after experimental welding. For this
purpose, samples of welded joints shall be prepared and tested in the presence
of the Engineer. The values once determined shall be maintained throughout the
work and if any modifications are to be made, a written permission of the
Engineer shall be obtained. In the case of thin sheets, electric arc welding may
not give satisfactory results and gas welding shall be resorted to. Gas welding
shall be subject to the same specifications and tests as those for electric welds.
Welding should be carried out inside as well as outside.
1..12.3 All the shop and field joints shall be welded, all welding shall conform to the
requirements of IS 9595 and IS 4353.
1..12.4 All circumferential joints shall be double welded butt joints. Field joints shall be
from outside, with a sealing weld from inside. End preparation for such welding
shall conform to IS: 2825.
1..12.5 All circumferential welds involving Coils of unequal thickness shall be so kept that
the inside surfaces of Coils match to provide stream lined joints without alteration
in the internal diameter. As far as practicable, welding of dissimilar thickness of
shells shall be carried out in the shops.
1..12.6 The welding shall be of the best workmanship free from flaws, burns, etc. and the
Contractor shall provide for his own electrodes and equipments, ovens to keep
the electrodes at the desired temperatures and dry. In order to maintain a good
standard in welding, welders shall be tested by the Contractor with prior
intimation to the client before they are entrusted with the job. Qualification
standard for welding procedures, welders and welding operation shall conform to
the requirements of IS: 7307 and IS: 7310 (latest). Periodical tests as regards
their efficiency shall also be taken at intervals of about 6 months and those found
inefficient shall be removed from the job. Only those who pass the test shall be
posted on the job. If an incompetent welder has already welded some pipes, all
welding done by him previously shall be fully checked by X-ray in addition to the
regular X-ray inspections. The defects if any shall be set right to the satisfaction
of the Engineer. All such check tests and rectification of defects shall be entirely
at the cost of the Contractor. No pipes or steel sections shall be erected unless
GWSSB 55
the work of the welder concerned has been proved to be satisfactory. Specially
selected welders shall do site welds.
1..12.7 A record shall be maintained showing the names of welders and operators who
have worked on each individual joint. Hand-welding shall preferably be carried
out by a pair of welders (parallel welding putting two welders at a time both will be
working in diametrically opposite side of the curvature. Welding shall be divided
into 4 quadrants shall be welded simultaneously, so that by observing proper
sequence, distortion can be avoided. A joint entrusted to a particular individual or
a pair shall be as far as possible, completed by them in all respects, including
sealing run. No helper or other unauthorized person shall be permitted to do any
welding whatsoever. In case of infringement of above, the persons shall be
punished as directed by the Engineer.
1..12.8 The welded joint after welding should not become brittle or sensitive to blows and
there should be no loss of toughness due to welding or heat treatment. The
material after welding and heat treatment is to be tougher than the base metal
and is to retain its original ductility. No allowance will be made for thinning of weld
and the weld should in no point be less than the nominal thickness of plate.
1..12.9 Upon receipt of the order and prior to the start of fabrication, the Contractor shall
submit to the Engineer for his approval the ``welding procedure'' he intends to
use in the shop work. Similarly, prior to the start of the field welding, procedure
for the field welding must be submitted to the Engineer for his approval. Manual
welding shall be adopted only when machine welding is not possible.
1.6ULTRASONIC& RADIOGRAPHIC TESTOF WELDED JOINTS
1.6.1MANUFACTUREDINSITE FACTORY/WORKSHOP
1.6.1.1 For the mild steel pipes manufactured in site factory/workshop, fabricated from
mildsteel Coils, 100 % of weld length of each pipe shall be subjected to Ultrasonic
Test either on line or off line. (As per API 5L)
1.6.1.2 For the mild steel pipes manufactured in site Factory/Workshop fabricated from
mild steel coils, 15% of weld length of each pipe shall be subjected to Radiography
Test by Digital Image/ X-Ray Film Method. (As per API 1104 or IS:10234)
1.6.2 FIELD WELDED JOINTS
1.6.2.1 For Field welded joints, 100% of each welded joint shall be examined by Ultrasonic
Test either on line or off line. In case of failure of joint the contractor shall be required to
carry out radiography of thrice the number of field joints failing during the
Ultrasonictest. Even after such radiography testing, if any one of the joint fails, the
contractorshall be required to carry out Ultrasonic and radiography of joints on all
field weldedjoints i.e. 100 % basis. All these testing’s shall be carried out by the
contractor at his own risk and cost.
1.6.2.2 The weld ripples or weld surface irregularities, on both inside and outside shall be
removed by any suitable mechanical process to a degree such that resulting
radiographic contact due to any remaining irregularities cannot mark or be confused
GWSSB 56
with that of objectionable defect. The radiograph shall be made in strict accordance
with the latest requirements and as per the latest and most efficient technique either
with X-ray or gamma ray equipment.
1.6.1.3 The photographs are to be marked in such a way that the corresponding portion of
the welded seam can be readily identified. All radiographs will be reviewed by the
Engineer to identify the defect and determine those which must be removed. Defects
that are not acceptable shall be removed by chipping, machining or flame gouging to
sound metal and the resulting cavities shall be welded. After rectification, the joint is
to be radio graphed again to prove the quality of the repair. The Engineer based on
the latest standards prescribed by Indian Standard specification will judge the
radiographs as acceptable or unacceptable.
1.6.1.4 All X-ray shall be made with equipment and by personnel furnished by the
Contractor. Films shall be developed within 24 hours of exposure and be readily
accessible at all times for inspection by the Engineer. The Contractor shall provide
for the use of the Engineer suitable X-ray viewing equipment. X-ray films shall be
properly maintained by the Contractor and shall be handed over to the department on
completion of the Contract. All films shall be identified by the No. and chart prepared
indicating location of the joint each X-ray photo represents. In the event of additional
radiographic inspections required of any work associated with the pipe erection, the
Radiographer at the discretion of the Engineer shall perform such inspection.
1.7 RADIOGRAPHIC INSPECTION

1.7.1 GENERAL
1..1.1 The Engineer shall assure himself that the welding procedure employed in the
construction of pipes has been qualified. The Contractor shall submit evidence to the
Engineer that the requirements have been met. The Contractor shall certify that the
welding of pipes has been done only by qualified welders and welding operators and
the Engineer shall ensure himself that only qualified welders and welding operators
have been used.
1..1.2 The Contractor shall make available to the Engineer a certified copy of the records of
the qualification tests of each welder and welding operator. The Engineer shall have
the right at any time to call for and witness tests of welding procedure or of the ability
of any welder and welding operator.
1..1.2.1 Radiographic Inspection of welded joints

1.1.1.1 All welded joints to be radiographed shall be examined in accordance with
IS : 2595- Code of Practice for Radiographic Testing
IS : 4853 Recommended Practice for Radiographic Inspection of Fusion Welded
Butt joints in Steel Pipes.
IS :1182 Recommended Practice for Radiographic Examination of Fusion

Welded Butt-Joints in steel Coils.
GWSSB 57
1..1.2.2 The reinforcement on each side of all butt welded joints shall not exceed 1.5 mm.
A complete set of radiographs and records as described in IS: 2595 for each job
shall be retained by the Contractor and kept on file for a period of at least five
years.
1..1.2.3 Radiographers performing radiograph shall be qualified in accordance with SNT-

TC-1A. Supplements and Appendices ``Recommended Practice for
Nondestructive Testing Personnel Qualification and Certification'' published by
the American Society for Nondestructive Testing as applicable for the technique
and methods used.
1..1.2.4 Final acceptance of radiographs shall be based on the ability to see the
prescribed pentameter image and the specified hole.
1..1.2.5 The acceptance criteria for radiography of the joint shall be as per IS-10234 or as
per API -1104 standard.
 THERMAL STRESS RELEIVING
Not applicable.
 TOLERANCE
1..1 The shell in the completed work shall be substantially round. The difference between
maximum and minimum inside diameters at any cross section shall not exceed 1% of
the nominal diameter of the cross section under consideration subject to a maximum
of 10 mm.
1..2 Machined parts shall be within the limits specified by IS 3589.
1..3 Straight pipes shall have their faces perpendicular to the axis of the section with a
maximum deviation of 2 mm on either side of the plane. Pipe ends shall be beveled
as per IS: 3589. The pipes shall be supplied in length of 10.5 meters to 12.5 meters.
1..4 For the shell thickness, no negative tolerances are acceptable.
1..5 SHOP TESTING
1..5.1 After fabrication, but before application of protective coatings all pipes and
specials shall be subjected to a shop hydraulic test (100%). Standard lengths of
pipes shall be directly subjected to test and non-standard pipe and elbows can be
tested as standard pipe before being cut to size.
GWSSB 58
1..5.2 FIELD HYDRAULIC TESTING
The Pipeline after lying at site shall be subjected to 100% Hydro testing.The test
pressure shall be 1.5 times working pressure or 6 kg/cm2 whichever is higher.
The pressure shall be maintained for a period of 24 hours. The length of pipe for
hydro testing shall be generally 5 km as directed by Engineer-In-Charge.
1..5.3 Each pipe shall be filled with water and the pressure slowly and uniformly
increased until the required test pressure is reached.
1..5.4 The pipe to be tested shall be given a serial no. which shall be painted on its
inside together with details such as pipe No. Shell thickness, diameter, length etc.
as directed. It shall be entered in the register to be maintained by the Contractor.
1..5.5 Prior to testing, the pipe shall be inspected thoroughly and all the apparent
defects in welding such as jumps, porosity etc. shall be repaired by gouge and re-
welding.
1..5.6 The hydraulic test shall be carried out under cover at the fabrication shop, in the
presence of and to the satisfaction of the Engineer or the inspection agency
appointed by the Employer.
1..5.7 For indicating the pressure inside the pipe an accurate pressure gauge of
approved make duly tested and calibrated for the accuracy of readings shall be
mounted on one of the closures which close the pipe ends.
1..5.8 The pressures shall be applied gradually by approved means and shall be
maintained for a period of 24 hours. The pipe shall be hammered throughout its
length with sharp blows, by means of a 1 kg. hand hammer.
1..5.9 The pipe shall withstand the test without showing any sign of weakness, leakage,
oozing or sweating. If any leak or sweating is observed in the welded joints, the
same shall be repaired by gouging and re-welding after dewatering the pipe. The
repaired pipe shall be re-tested to conform to the specified pressure.
1..5.10 If any leak or sweating is observed in pipe shell the pipe under test shall be
rejected temporarily. The Contractor shall stack such rejected pipes separately in
his yard. The Engineer shall inspect the same and after taking cuts if necessary,
shall determine the nature of repairs to be carried out thereon and shall then
decide as to how and where they shall be used. No payment shall be made for
handling or carrying out repairs, but, payment for the fabrication and hydraulic
testing of the pipe shall be released only after acceptance of the pipe with
necessary repairs and subsequent testing etc. are carried out by the Contractor
to the satisfaction of the Engineer. The Engineer shall be supplied with two
copies of the results of all the tests carried out.
GWSSB 59
The Mechanical Tests for Pipe material at Manufacturers work shall be carried as per
approved Quality Assurance Plan( QAP) and tests shall be as per IS:1239/ IS:3589/IS:5504.
1..5.11 Testing Of Site Welded Joints

(i) The welded joints at site shall be tested for Tensile test, Bend test & Tre-
panned plug in accordance with procedure laid down in as per the latest edition
of IS No. 3600 “code of procedure for testing of fusion welded joints and weld
metals in steel”.
(ii) Test pieces shall be taken by the contractors from the welded joints at the
position on fabricated pipes pointed out by the Engineer in-charge.
(iii) The sample so taken shall then be cut to the exact shape and dimensions and
machined as described below and handed over to the Engineer-in-charge for
testing. All the work up to and including machining and arranging for test shall
be done by the contractors.
1..6 SUBMISSION OF DAILY PROGRESS REPORT
1..6.1 The Contractor shall submit to the Engineer a daily progress report in the
proforma approved by the Engineer, wherein all the details of the work carried out
in the factory shall be fully recorded. Similarly, works done in the various units in
the factory shall be separately mentioned. The Contractor shall maintain a
register of all the finished materials giving dates of carrying out important
operations such as testing, transport, etc. The register shall be presented at least
once a week to the Engineer who shall initial the entries after verification.
 TRANSPORTING OF PIPES, SPECIALS etc.
1..1 All pipes and specials fabricated in the site factory / workshop and temporarily
stacked in the Contractor's yard shall be transported to the site of laying after
cleaning them internally etc. The loading in the factory shall be carried out by
means of either a crane, gantry or shear legs, so as not to cause any damage to
the finished material. Similarly, while unloading and stacking, great care shall be
taken to ensure that the material is not damaged or dented. The contrivances to
be used for unloading will be different in different situations and in each case the
one approved by the Engineer shall be adopted. The material stacked at site
shall be jointly inspected by the Engineer and the Contractor and defect or
damage noticed shall be repaired to the satisfaction of the Engineer before
payment is admitted.
1..2 Props of approved designs for maintaining circularity having M.S. Angle/Pipe at
both ends to avoid metal to metal contact shall be fixed to the pipes during transit
to avoid undue sagging and consequent distortion. After the pipes are carefully
stacked, props should be retained till pipes are joined in trenches and then props
are re-used for subsequent similar operations. The stacking ground, both in the
Contractor's yard and at the site of laying shall be selected in such a way as not
to get waterlogged during monsoon. If this cannot be done, the pipes shall be
supported on sleepers to avoid contact with wet earth and subsequent rusting. In
order to prevent sagging during transit, savings of steel Coils can be utilized by
GWSSB 60
cutting to the required length and tacking the same to the pipe ends, in place of
props, if approved by the Engineer.
1..3 As explained in earlier paragraphs, materials such as pipes, tapers, etc. may be
transported to the site of laying as soon as the material is finished in all respects
with the permission of the Engineer to avoid congestion in the Contractor's yard.
However, materials such as expansion joints, composite bends, `T' branches and
other complicated materials shall be stacked in the Contractor's yard until they
are required for laying in the field. In view of this, the work of fabrication of such
materials shall be properly synchronized as far as possible with the laying
operations.
1..4 Fabricated materials such as specials, appurtenances, bolts, nuts, distance

pipes, flanges, saddles, collars bypass arrangements etc. shall be transported to
the site of laying from the fabrication shop according to the needs of the laying
operations only. In regards access roads, the Contractor shall note that access
road may lead up to some points on the alignment the Contractor shall have to
make his own arrangement for connecting approaches to transport the pipes
cross country to the actual site of laying at his own cost. Whatever may be the
mode of transport he uses it shall be incumbent on the Contractor to carry and
stack the pipes and specials along the alignment as close as possible to the site
of laying.
 PROCEDURE FOR RECEIVING STEEL PIPES
1..1 General
1..1.1 To ensure that the work of erecting pipes is not held up at any stage and place,
the Contractor shall maintain an adequate stock of standard specials, flange
rings, plug Coils, manhole covers, etc. and short length of smaller diameter
pipelines, etc. at site in his field stores, in consultation with the Engineer.
Wherever possible, the Contractor shall arrange one full month's requirement of
pipes, specials, etc. stacked along the alignment.
1..2 Stacking of Pipes, etc. and Inspection
1..2.1 The Contractor shall keep in each section a responsible representative to take
delivery of the pipes, specials and appurtenances, etc. transported from the
fabricating stockyard or received from any other work site to the site of laying and
to stack along the route on timber skids. Padding shall be provided between
coated pipes and timber skids to avoid damage to the coating. Suitable gaps in
the pipes stacked shall be left at intervals to permit access from one side to the
other. The pipes, specials, appurtenances so received on site shall be jointly
inspected and defects recorded, if any, such as protrusions, grooves, dents,
notches, damage to the internal coating etc. shall be pointed out immediately to
the Engineer at the site and in the acknowledgement challans. Such defects shall
GWSSB 61
be rectified or repaired to the satisfaction of the Engineer entirely at the

Contractor's risk and cost.
1..3 Handling of Pipes, Special Appurtenances etc.
1..3.1 It is essential to avoid damage to the pipes, fittings and specials, etc. or their
coatings at all stages during handling. The pipes and specials shall be handled in
such a manner as not to distort their circularity or cause any damage to their
surface treatment. Pipes shall not be thrown down from the trucks nor shall they
be dragged or rolled along hard surfaces. Slings of canvas or equally non-
abrasive materials of suitable width of special attachment shaped to fit the pipe
ends shall be used to lift and lower coated pipes to prevent damage to the
coating.
1..3.2 Great care shall be taken in handling the pipe right from the first operation of
manufacture until they are laid and jointed. The Contractor will provide temporary
props as described earlier in order to prevent any sagging of the pipes while they
are stacked in their yard and while transporting to the site of delivery, i.e. laying.
The props shall be retained until the pipes are laid and welded. If at any time
these props are found to be dislodged or disturbed, the Contractor shall
immediately reinstate them in such a way that the true shape of the pipe shell or
specials is maintained to the satisfaction of the Engineer. No defective or
damaged pipe or special shall be allowed to be used in the work without
rectification to the satisfaction of the Engineer. Any damage to the coating shall
be repaired by the Contractor at his own cost to the satisfaction of the Engineer.
1..4 Dents
1..4.1 Whenever any dent, i.e. a significant alteration of the curvature of the pipe shell is
noticed, the depth of the dent shall be measured between the lowest point of the
dent and the pipe shell curvature line. All dents exceeding 2 percent of the outer
diameter of the pipe shall be removed by cutting out a cylindrical portion of the
pipe and replacing the same by an undamaged piece of the pipe. The Engineer
may permit insert patching if the diameter of the patch is less than 25 percent of
the nominal diameter of the pipe. Repairs by hammering with or without heating
shall not be permitted. Any damage to the coating shall also be carefully
examined and rectified.
1..5 Marking
1..5.1 The component parts of the pipes shall be carefully marked for identification in
the field. The marking shall be on the side which will be the inside of the pipe
after bending.
1..5.2 The marking operation shall be conducted with full size rulers. Only blunt nose
punches should be used.
GWSSB 62
1..5.3 The Coils used for fabrication of pipes shall be laid out in such a way that when
the shells are completed one set of original identification markings for the
material will be plainly visible. In case these markings are unavoidably cut out,
they shall be accurately transferred by the Contractor to a location where these
markings will be visible on the completed work.
1..5.4 After the hydraulic tests on the specials and other items, the number of the shell
in the line as it will be erected and the direction of flow shall be stamped in a
prominent manner on each piece.
1..5.5 A register shall be maintained in suitable Performa giving the following

information for each shell tested:
(a.) Serial No.
(b.) Shell No.
(c.) Date of test
(d.) Thickness and specification of steel
(e.) Weight of shell tested
(f.) Maximum test pressure
(g.) Details of test performance
(h.) Details of radiographic examination of welds
(i.) Name of Engineer's representative witnessing tests
1..5.6 A copy of these details shall be furnished to the owner free of cost.
1..5.7 No separate payment will be made for these markings and the rates for the items
concerned shall be deemed to include the cost of such markings.
 LAYING OF PIPELINE
1..1 General
1..1.1 Unless specified otherwise, the pipeline shall be buried with minimum cover at
top, as shown on drawings. No material shall be erected unless it has been
previously passed by the Engineer.
1..1.2 Pipe shall be protected from outside with rock shield mesh/soft murum/Sand
wherever required/as directed by Engineer-In-Charge. In such cases, the depth
of soft murum/sand shall be 300mm above top of pipe. The mesh shall be
manufactured from HDPE material with weight per meter not less than 750
grams. The size of mesh shall be as per requirement of engineer-in-charge. The
mesh shall be of such strength to protect the external coating from impact of rock
during back filling.. The height of falling of rock shall range from 3 to 5 mts over
top of pipe. The mesh shall be spirally wrapped over pipe with suitable overlap
and properly tied with non metallic ties. The mesh shall be spirally wrapped over
pipe with suitable over lap. After field joints and at all specials also shall be
wrapped by rock shield protection mesh
GWSSB 63
1..1.3 Erection of fabricated shells shall be carried out by the Contractor who shall
equip himself, at his cost, with all necessary tools, machinery, labor etc. required
for the purpose.
1..1.4 Welding
Except for routine welding of joints, no other work shall be done in the absence of
Contractor's engineer, either during the day time or at night.Chipping shall not be
kept in arrears for more than 15 joints.
1..1.5 Temperature
The components of the pipeline such as base Coils, top Coils and pedestals have
been so designed that the centers of the Coils and pedestals shall coincide at the
Mean Temperature (30o).
For this reason, all works such as fixing flanges, base plate etc. in true alignment
and in correct position and tack welding pipes shall be done at the mean
temperature.
For ascertaining the temperature, the Contractor shall provide mercury cups and
fix them to the pipe shell from outside and shall also provide thermometers of the
required type and range. No extra payment shall be made for this.
1..2 Saddle supports
1..2.1 Unless otherwise specified pipeline shall be underground. However at

unavoidable reaches it shall be on R.C.C. saddles spaced at about 6 m center to
center. The material and construction of R.C.C./Steel structures such as saddles,
anchor blocks, crossings etc. associated with the work of pipe line shall conform
with the relevant I.S. codes, good engineering practice and as directed by the
Engineer. The pipes to be laid on saddle supports shall be erected at mean
temperature. Saddle supports shall either be sliding type or fixed type. For both
the types of supports a 10mm thick double plate shall be welded to the part
circumference of the pipeline that will make contact with the saddle and another
similar plate shall also be embedded in the concrete saddle with necessary
arrangement to facilitate welding it to the double plate welded to the pipe, in case
of fixed support. In case of sliding support, the pipe shall be allowed to slide
freely over the plate embedded in the saddle. Alternatively to achieve fixity, the
pipe shall be anchored by providing suitable anchor block. The rate for laying the
pipe on saddle support shall include for laying, aligning, tack welding, provision of
rigging screws with screw eyes etc., complete.
1..2.2 In addition to above, the pipe shall be held in position on saddles with two
numbers 50mm x 8mm thick holding down traps fixed to the saddles with holding
down bolts and nuts.
1..3 Erection of Shells
1..3.1 The erection shall be true to position, lines and grade of the trench prepared or
as modified by the Engineer. The Contractor shall provide at his cost necessary
saddles, pads, spider etc., all necessary instruments and other materials and
GWSSB 64
labour required for proper erection of shells in position and for the Engineer in
checking the correctness of the erection.
1..3.2 Alignment of sections at edges to be butt welded shall be such that the maximum
offset is not greater than the values given below:
Offset in Longitudinal joints Offset in Girth joints (mm)

(mm)
Thickness ‘t’ (mm)
Up to 12 0.25 t 0.25 t
12 to 20 3 mm 0.25 t
20 to 40 3 mm 5 mm
40 to 50 3 mm 1/8 t
Over 50 1.1.1.1.1.1.1 Lesser of Lesser of 0.125 t or 20 mm

0.0625 t or 10
mm
1..3.3 The best of welders as selected from their work in the Contractor's workshop
shall be selected for in-situ welding of the shells. The relevant provision under
welding such as qualification standard for welding procedures, tests on welder's
work and removal of defects etc., shall also apply to in-situ welding.
1..4 General Sequence of Operations
1..4.1 Before commencing the work of pipe laying, the Contractor shall study the L-
section of the pipeline for the section concerned. He shall also study the details of
laying i.e. underground or aboveground. The underground pipeline shall be laid
on sand cushioning/ bedding as shown on the drawing. The difference in depth
due to uneven excavations shall be made up by sand cushioning.
1..4.2 Pipe laying shall generally start from the fixity points on either side, the expansion
joints if required for pipeline aboveground being provided last. Fixing points are at
all anchor blocks. Where such blocks are not required for long lengths, fixity shall
be achieved by fixing the pipeline to the special type of R.C.C. or steel saddles as
specified. The distance between successive fixity points shall not exceed 300 m.
1..4.3 Thrust and Anchor blocks shall be constructed before commencing the pipe
laying work in any section. The construction of the blocks shall be carried out in 3
stages: in the first stage the lower part up to 150 mm below the invert of the
pipeline including concrete chairs to support it shall be constructed; in the second
stage the pipeline on this part of the block shall be laid; and lastly, the remaining
block around and over the pipeline shall be constructed.
GWSSB 65
1..4.4 The fixity saddles and ordinary saddles if the pipeline is aboveground shall be
cast-at least 3 weeks before the pipeline is laid on them. After all saddles
between successive fixity points have been cast, a line plan showing the actual
position thereof shall be prepared, after taking levels and measuring distances. In
case of any errors in casting the pedestals, corrections shall be applied. The pipe
laying work shall then start from the fixity points and shall proceed towards the
expansion joints. The method of jointing the pipes and erecting them on
previously cast R.C.C. saddles shall be determined by the Contractor depending
upon the type of plant equipment and personnel available with them.
1..4.5 The pipe strakes shall be assembled in position on the saddles either by the
cranes, portable gantries, shear legs or any other equipment approved by the
Engineer. Normally, not more than two pipes shall be aligned, tacked and kept in
position on temporary supports. The Contractor shall not proceed with further
work, until the circumferential joints of these pipes are fully welded. During
assembly, the pipeline shall be supported on wooden sleepers and wedges, with
the free end of the pipeline held in position by slings to avoid deflection due to
temperature variations during the day. In general, the assembly of pipe strakes
and one run of welding shall be done during the day time while full welding
including the external gouging and sealing runs shall be done after 5 p.m. or so.
The Contractor shall maintain the continuity of the work by adding two more pipes
on the second day in a similar manner, after full welding of the previous joints is
completed during the night. While this new work is being done, the Contractor
shall proceed with the work of providing permanent supports for the pipeline
assembled and welded previously.
1..5 Fixing Expansion Joint
The work of laying pipeline at above the ground, laying starts from the fixity
points and proceeds towards the expansion joints. It shall be continued until the
gap between the pipe ends is less than the lengths of the expansion joint plus
pipe strake length. At this stage, the exact gap between the pipe ends shall be
measured at mean temperature of that locality. Let it be `X'. Similarly, the exact
length of the pipe strake and the expansion joint bought at site shall be
measured at the same temperature let these be `Y' and `Z' respectively.
Normally, the length of the expansion joint (`Z') is standard.
(a) Case when `Y' plus `Z' is more than `X' or equal to `X' (i.e. fixing of expansion
joint without strip)
At mean temperature the exact gap between pipes shall be measured. Free ends
of pipes shall be brought in a correct line and level; lateral movement, if any, shall
be corrected. Then the gap between the free ends shall be made equal to the
exact length of the expansion joint by cutting one of the pipe ends. Choice of the
end to be cut must be made from the point of view of bringing the expansion joint to
a central position.
The expansion joints are normally supplied without packing. The normal length of
the expansion joint shall be reduced by about 100 mm by cutting the inside locks
and inserting the inner strake by means of turn buckles. At mean temperature this
expansion joint shall be inserted inside the gap (care being taken to keep the
GWSSB 66
tapered portion on the down-stream side), and both ends shall be tack welded to the
pipe ends, after pulling the expansion joint. (Tacks of these two joints shall be of
longer length, approximately 100 mm long).
Welding of these two joints of the expansion joints shall be started only after it is
ascertained by taking observations that the expansion joint is functioning properly.
The procedure to be followed for taking observations as specified .
Case when `Y' plus `Z' is less than `X' (i.e. fixing of expansion joints with strap)
The expansion joint shall be laid in locked position. Before laying the pipes adjacent
to the expansion joint, the exact gap between the pipes shall be calculated by taking
measurements of the first pipe (upstream of the expansion joint), and the second
pipe (downstream of the expansion joint) at Mean Temperature.
If the gap is less than 100 mm, the second pipe shall be cut to make the desired
gap of at least 100 mm. If the gap is more than 200 mm, suitable distance piece of
not less than 600 mm shall be inserted after cutting necessary length of the first
pipe.
The second pipe shall then be laid in position. Then a strap of length equal to three
times the gap length shall be welded to the pipe, overlapping the second pipe by the
gap length. The other end of the strip shall be kept free.
At mean temperature the other end of the strap shall be tacked to the first pipe, after
checking of the line and level. Simultaneously, all the locks of the expansion joint
shall be removed and chipped off properly.
Welding of the joints between the strap and the first pipe shall be started only after
observations are over and it is ascertained that the expansion joint is functioning
properly.
Observations
Before fixing the expansion joint, two mercury cups - one on the left and the other
on the right side - shall be fixed on the pipe near the upstream side of the expansion
joint.
Immediately after the expansion joint in case (a) above or the strap in case (b)
above is tack welded, observations for total expansion or contraction shall be
started and continued for 48 hours round the clock. Similarly, the central and end
fixity pedestals shall be kept constantly under observation.
The expansion and contraction shall be measured by making a temporary marking

on the inner strake (on the upstream side) and measuring the distance between this
mark and the edge of the gland of the expansion joint.
The observations shall be recorded in the following Performa;
GWSSB 67
Reading Time Shell temp on Shell temp on Atmospheric Dist between

No. upstrea downs temp edge of
m side tream eratur gland
side e and
marking
1 2 3 4 5 6
1..5.1 In case the pipeline is laid in trenches as shown on the drawing, after welding
and field testing, the trench shall be filled with selected material up to 300 mm
above pipes. This backfill shall be provided in layers not more than 150 mm, with
a density more than 70 to 80% of the standard proctor density. Samples shall be
tested as directed by the Engineer. Remaining depth of trenches shall be filled
with ground backfill material.
1..6 Specials
1..6.1 General
Specials, such as tees, Y-pieces, bends (single or composite), tapers, etc. shall
necessarily be in steel and shall be manufactured as per standards and tested
and laid in the same manner as the pipes. Small branches, single piece bends,
etc. may be fabricated at site, care being taken to ensure that the fabricated
fittings have at least the same strength as the pipeline to which they are to be
jointed.
1..6.2 Bends
(a) Bends shall be fabricated taking into account the vertical and horizontal angles
for each case.
(b) The bends shall have welded joints and the upstream and downstream ends of
each bend shall have a straight piece of variable lengths as required.
(c) Bends shall be designed with deflection angle of maximum 10 deg. between
segments.
(d) When the point of intersection of a horizontal angle coincides with that of a
vertical angle, or when these points can be made to coincide, a single combined
or compound bend shall be used, designed to accommodate both the angles.
The combined bend should have a pipe angle equal to the developed angle,
arrived at from appropriate formula.
(e) All joints in bends shall be thermally stress relieved as specified.
(f) Details of thrust collars anchor bolts, holding down straps, saddle Coils should be
furnished together with full specifications in Contractor's fabrication drawing.
1..6.3 Manholes
(a) Manholes of 750-mm dia shall be provided at both the sides of butterfly valves
and as directed by Engineer-In-Charge. Manholes in the pipeline shall be placed
in suitable position in the top quadrant.
GWSSB 68
(b) The Contractor shall fabricate different parts of manhole in conformity with
relevant IS Specification, well-established practices and as directed by the
Engineer.
1..6.4 Closing or Make up sections
Closing or make up sections shall be furnished at appropriate locations on the line

to permit field adjustments in pipeline length to compensate for shrinkage in field
welded joints, differences between actual and theoretical lengths and
discrepancies in measurements.
1..6.5 Heads
Test heads may be ellipsoidal, standard dished as per ASME code or

hemispherical heads. They shall be welded in the shop and removed after the
test. Allowance should be made in the length of the pipe section receiving the test
head for the welding and removal of the head and preparation of the plate edges
for the final weld after testing.
No separate payment will be made for such test heads. The rate quoted for the
hydraulic test shall be deemed to cover the cost of such installations.
1..6.6 Walkways, Stairs, Ladders, Hand Rails etc.
Walkways, stairs, rungs, ladders, hand rails, etc. shall be provided as shown in the
drawings and/or as directed by the Engineer. They shall conform to well
established design and construction for each accessory concerned.
1..6.7 Flanges
Flanges shall be provided at the end of pipes or special where sluice valves, blank
flanges, tapers, etc. have to be introduced. The flanges received from the
manufacturers will have necessary bolt holes drilled. The Contractor shall
assemble the flanges in the exact position by marginal cutting, if necessary, so as
to get the desired position of the sluice valves, etc. either vertical or horizontal and
shall then fully weld the flanges from both sides in such a way that no part of the
welding protrudes beyond the face of the flanges. In case the welding protrudes
beyond the flanges and if the Engineer orders that such protrusions shall be
removed, the Contractor shall file or chip them off. If required and when ordered
by the Engineer, the Contractor shall provide and weld gusset stiffeners, as
directed on site. The drilling pattern shall be matching with the drilling pattern of
flanges of valves.
1..6.8 Blank Flanges
Blank flanges shall be provided at all ends left unattended for the temporary
closure of work and also for commissioning a section of the pipeline or for testing
the pipeline laid. For temporary closures, non-pressure blank flanges consisting of
mild steel Coils, tack welded at the pipe ends may be used. For pipes subjected to
pressures, the blank flanges or domes suitably designed as per Engineer's
requirements shall be provided.
GWSSB 69
1..6.9 Stiffener Rings
The Contractor shall provide stiffener rings wherever required by design. The
Contractor shall weld the same to the pipes with one circumferential run on each
side.All fillet welds shall have a throat thickness of not less than 0.7 times the
width of welding.
1..7 Field Hydraulic Test
After erection at site and after the concrete Thrust/anchor blocks have been
constructed, the pipeline shall be subjected to a 100% hydraulic test.The
pressure test shall be conducted in as per IS-5822.
1..7.1 During the test, the pipe shall be struck sharp blows with 1 Kg hammer. Water
shall not spout, ooze or sweat either through joints-welded or bolted or the body
of the pipe. If any leakage noticed shall be repaired by the Contractor, which shall
include coating and repairing of the damaged portion. Repairs and replacements
and further testing including the cost of the Coils and other raw materials shall be
carried out by the Contractor at his own cost. If any leakages are observed during
the defects liability period due to defective workmanship or material supplied by
the Contractor, he shall repair the same to the entire satisfaction of the Employer,
at his own cost.
1..7.2 GWSSB shall assist the contractor in identifying the source & in obtaining
permission for drawl of water for field-testing of pipe. The contractor shall pay for
the water and carry the water to the test location at his cost. The cost of hydraulic
testing of the installation by providing necessary testing equipment, pumping the
water, creating and maintaining pressure, and the necessary bulk heads and their
fixtures, and their subsequent removal and restoring the installation to working
trim shall be included in the rate for laying and testing of the pipe.GWSSB may
also provide water for testing and civil construction work from its adjacent pipeline
at a rate of Rs. 4/- per Kiloliter, if feasible. Contractor shall seek prior permission
of deptt in writing and shall water meter at his own expense.
1..8 Progress in Laying
1..8.1 The tenderer shall submit along with the tender his detailed bar chart for
manufacturing and laying of the pipeline. While preparing his bar chart, the
tenderer shall plan his activities such that the laying of pipes shall closely follow
the manufacturing schedule and no pipes shall remain stacked in factory or at
site for a period more than two months.
1..8.2 It is mandatory that he shall submit an approach note on how he will carry out this
Work within the contractual period and on the compatible resources in terms of
construction equipment and other facilities that he shall utilize to complete the
tendered Work.
1..8.3 Field Destruction Test

Contractor shall perform destruction test of any section of MS Pipeline which
Engineer selects at every 5 KM pipeline laid and shall submit its result to him.
GWSSB 70
The testing shall be done in the NABL approved laboratory in the presence of
representative of the employer.
INTERNAL COATING: SOLVENT FREE FOOD GRADE EPOXY LININGS
2.1 GENERAL
All steel pipes and fittings outside the pumping station shall be internally lined with a
spray applied solvent free epoxy approved for contact with potable water under the
United Kingdom Water Regulations Advisory Scheme authorized for use under
Regulation 31 (4)(a) of the water supply (Water Quality) Regulations 2000 for contact
with potable water. The applicable specifications for the coating system shall be in
accordance with BS 6920/NACE RP-01-75/AWWA C210-97/CAN-CSA Z 245:21 or
clients specifications.
2.1.1 MATERIALS & WORKMANSHIP

The coating system shall be factory lined and the lining shall be suitable for
application in an environment with black bulb temperature up to 85 deg C.Coating
materials shall be of GWSSB approved make only.
All steel pipes shall be lined at the factory. Pipes welded on site shall be lined on site
to the same standards as for pipes.
Detailed proposals of the lining method, materials and apparatus to be used for both
factory and site application shall be submitted to and approved by the Engineer
before work starts. Storage and application shall be accordance with
recommendations of the coating manufacturer, but as a minimum:
a) A visual examination of the surface to be coated shall be carried out and any
slivers or similar deposits removed.
b) Prior to blasting all oil and grease shall be removed from the surface to be coated.
c) Preparation of steel surfaces for both factory and site application shall be to a
minimum of Sa 2.5accordance with BS 7079/ ISO 8501-1:2007 specifications /or
as per client specifications and roughness should be 50-75 micron.
d) The surface to be coated shall be dry, clean and free from foreign material and
coating shall take place before any surface rusting and at least within 4 hours of
blasting.
e) Surface preparation and coating shall not be carried out when the relative humidity
exceeds 85% or when the surface to be coated is less than 3 deg C above the
dew point.
f) The coating shall have a minimum DFT (DryFilm Thickness) of 406 microns.
g) Coatings shall be used within the pot life specified by the manufacturer.
Pipe linings shall be inspected on site, and damaged, defective or otherwise

unsatisfactory linings may be condemned. All defective areas shall be made good to
the satisfaction of the Engineer. Inspection and testing shall be detailed in the
contractors Quality Plan and as a minimum undertaken to the following frequencies:
a) Visual Inspection of blasted profile on every pipe to be coated.
b) Visual inspection of finished coating on every pipe.
c) Measurement of coating thickness at four points on each pipe
d) Each completed pipe shall be subjected to holiday detection tests which shall be
carried out to the satisfaction of the Engineer. The applied voltage shall be those
appropriate to the coating under test as recommended by the coating material
manufacturer.
e) Peel Test as per Manufacturers standard specification shall also carried out.
GWSSB 71
2.2 PRESERVATION, MARKING AND SHIPPING PRESERVATION
2.2.1 Preservation
Cutback of minimum 150 mm +/- 10mm shall be provided over both ends of pipes on
internal coating. The bare ends of each pipe shall be painted outside with a
removable vanish as temporary corrosion protection during transportation.
Spiders and/or Bevel protectors of a type to be approved by the Engineer shall

protect the bare ends of each pipe. Spiders shall be welded with pipes in such a way
that inside coating do not get burnt.
2.2.2 Marking
In addition to the marking required by API 5L, the specification MO1 "Steel Pipes for
Mainlines and other applicable project specifications, the Pipe Coating Contractor's
unique coating number shall be marked to the internal surface or the pipe with
synthetic resin paint.
Further marking details like color coding etc. shall be agreed upon with the Engineer.
The marking shall have at least a distance or 150 mm to the pipe end.
2.2.3 Shipping
Shipping and Loading preparation shall be in accordance with API Specification 5L or

otherwise stated in the contract documents.
The Pipe Coating Contractor shall submit detailed loading, stacking- and shipping
procedures for approval by the Engineer.
2.3 DOCUMENTATION
2.3.1 Pre-Production Documentation

The Pipe Coating Contractor shall submit the following documents to the Engineer for
approval prior to commencing production:
a) The manufacturer’s trade name and data sheets for all proposed coating
Materials. This includes cleaning and abrasive blasting consumables.
b) Procedure for identifying or maintaining the identification of each coated item.
c) Handling procedure.
d) Stacking procedure.
e) Materials control and traceability procedure for the batches of coating

materials.
GWSSB 72
f) Materials storage procedure (pipe and coating materials) I
g) Procedure for steel surface preparation including materials, cleaning.

inspection, verification of cleanliness and surface profile.
h) Coating application procedures, including fusion bonded epoxy (FBE).

Adhesive and polyethylene layers.
i) The results of the batch tests for batches to be used for pre-qualification tests.
j) Details of testing methods including instrument types and copies or current
calibration certificates.
k) Details of inspection methods for bare and coated pipe.
l) Full test results from the coating Procedure Qualification Test (PQT).
m) Repair procedure and results or tests on demonstration of repairs.
n) Project specific Quality Plan.
Work shall not commence until these procedures have been reviewed and approved
by the Engineer.
The selection of proposed coating materials shall be subject to Engineer's
approval.
2.3.2 Production Records

A daily log containing the following data shall be maintained and be available for
inspection by the Engineer during and/or after production. Data shall be recorded
against the pipe unique identification number.
a) Bare pipe inspection data
b) Ambient temperature (every 4 hours)
c) Humidity (every 4 hours)
d) Coating progress (no. of items coated. including item serial numbers) e} Blast
pipe surface amplitude
e) Tests for cleanliness of blast surface
g) Tests for cleanliness or blast medium
h) Film thickness measurements
i) Average, maximum and minimum coating thickness during each shift
j) Details of any coating defects recorded and defect density on respective
pipe lengths
k) Details of any coating repairs
l) The unique identification number of all items that are stripped for recoating
m) Pipe coating test results
GWSSB 73
This log shall be available to the Engineer throughout all coating operations
2.3.3 Release Documentation
The Pipe Supplier and/or Pipe Coating Contractor shall submit to the Engineer the
following documentation in hard copy and softcopy (format to be agreed upon with
the Engineer) with each batch of pipes released:
a) Mill certificates for line pipe
b} Production listing for each batch
c) Unique pipe identification numbers
d) Unique coating identification number (if different)
e) Pipe length
f) Length of the coated portion of each pipe and total coated lengths of all
pipes.
g} Reductions in lengths due to use in tests, damage or repairs, recorded

against pipe unique identification number
h) Date or coating
i) Batch numbers of coating materials used
This shall be followed within two weeks by the following:
a) Manufacturer's certificates for each batch of coating materials
b) Certification/calibration certificates for all testing and coating equipment
c) Inspection and test records, results, and other documentation of all
materials and coating tests
All reports shall be signed by the Pipe Coating Contractor to signify compliance with
the requirements of this specification.
GWSSB 74
3 EXTERNAL COATING: 3-LAYER POLYETHYLENE (3LPE)
SCOPE
This Specification defines the minimum requirements for the application of three-layer
polyethylene coating to the external surface of steel pipes and internal surface of steel
pipes with solvent free liquid epoxy lining for water transmission pipe line.
For the factory applied coating the system shall comprise of a layer of fusion bonded
epoxy (FBE), overlaid with adhesive with an outer layer for high density polyethylene
(HDPE) and internally lined with a air less spray applied solvent free epoxy.
3.1 CODES AND STANDARDS
This latest edition of the following codes and standards shall establish the minimum
standards for the work
ANSI/AWWA C213 Standard for Fusion-bonded Epoxy Coating for the

Interior and Exterior of Steel Water Pipelines
ASTM D149 Standard test method for dielectric breakdown voltage

and dielectric strength of solid electrical insulating
materials at commercial power frequencies.
ASTM D257 Test methods for dc resistance or conductance of

insulating materials.
ASTM D570 Standard test method for water absorption of plastics
ASTM D638 Standard test method for tensile properties of plastics
ASTM D746 Standard test method for brittleness temperature of

plastics and elastomers by impact.
GWSSB 75
ASTM D790 Standard test method for flexural properties of

unreinforced and reinforced plastics and electrical
insulating materials.
ASTM D1238 Standard test method for melt flow rates of

thermoplastics by extrusion plastometer.
ASTM D1505 Standard test method for Density of plastics by the

Density-Gradient Technique.
ASTM D1525 Standard test method for Vicat softening temperature of

plastics.
ASTM D1531 Standard test methods for relative permittivity (dielectric

constant) and dissipation factor by fluid displacement
procedures.
ASTM D1603 Standard test method for carbon black in define plastics
ASTM D1928 Standard practice for preparation of compression-

molded polyethylene test sheets and test specimens.
ASTM D2240 Standard test method for rubber property – durometer

hardness.
ASTM D3417 Standard test method for enthalpies of fusion and

crystallization of polymers by differential scanning
calorimetry (dsc)
ASTM D4703 Standard test practice for compression Molding

Thermoplastic Materials into Test Specimen, Plaques
or Sheets.
GWSSB 76
ASTM F372 Standard test method for water vapor transmission rate
of flexible barrier materials using an infrared detection
technique
AWWA C 200-97 Steel water pipe line
ASTM G8 Standard test method for CathodicDisbonding of

pipeline Coatings.
CAN/CSA Z 245:1 Internal fusion bond epoxy coating / lining of steel pipes.
DIN 30670 Polyethylene Coatings of Steel pipes and Fittings –

Requirements and Testing.
DIN EN ISO 9001 2000 Quality management systems – Requirements
DIN EN ISO 8501-1 Preparation of steel substrates before application of

paints and related products – Visual assessment of
surface cleanliness – Part 1 : Rust grades and
preparation grades of uncoated steel substrates and of
steel substrates after overall removal of previous
coatings.

paints and related products – Tests for the assessment
of surface cleanliness – Part 2 : Laboratory
determination of chloride on cleaned surfaces.

of surface cleanliness – Part 3 : Assessment of dust on
steel surfaces prepared for painting (pressure-sensitive
tape method)
GWSSB 77

of surface cleanliness – Part 4 : Guidance on the
estimation of the probability of condensation prior to
paint application.

of surface cleanliness – Part 9 : Field method for the
conductometric determination of water-soluble salts.
DIN EN ISO 8503-1 Preparation of steel surfaces before application of

paints and related products. Method for the grading of
surface profile of abrasivety blast cleaned steel using a
comparator (1995)

paints and related products – Surface roughness
characteristics of blast-cleaned steel substrates – Part
1 : Specifications and definitions for ISO surface profile
comparators for the assessment of abrasive blast
cleaned surfaces.

paints and related products – Surface roughness
characteristics of blast-cleaned steel substrates – Part
2 : Method for the grading of surface profile of abrasive
blast-cleaned steel – comparator procedure.
ISO 8502-5 Preparation of steel substrates before application of

of surface cleanliness – Part 5 : Measurement of
chloride on steel surfaces prepared for painting (ion
detection tube method)
NACE RP0490 Holiday Detection of Fusion-Bonded Epoxy External

Pipeline Coatings of 250 to 760mm (10 to 30 mils)
GWSSB 78
NACE RP-01-75 Recommended practice : control of International

corrosion in steel pipe line system.
SIS 05-5900 Preparation of steel substrates before application of

paints and related products – visual assessment of
surface cleanliness – PT 1 : rust grades and
preparation grades of uncoated steel substrates and of
steel substrates after overall removal of previous.
3.1.1 GENERAL
3.1.1.1 Environmental Conditions
The environmental conditions operating conditions, product data, etc. under

which the pipes shall operates and defined in Documents. Scope of Work,
Project Design Data and Site Conditions and Specification for Pipeline
construction.
3.1.1.2 Definitions
The terms “Contractor”, “Pipe Supplier”, “Pipe Coating Contractor”,

“Engineer”, etc. used in this specification shall have the meanings defined in
the General and Special Conditions of Contract.
3.1.1.3 Abbreviations
ANSI American National Standards Institute
API American Petroleum Institute
ASME American Society of Mechanical Engineers
ASTM American Society for Testing and Materials
DIN German Standards Institute
ISO International Organization for Standardization
NACE National Association of Corrosion Engineers
NPS Nominal Pipe Size
MPI Magnetic Particle Inspection
UT Ultrasonic Testing
GWSSB 79
SIS Swiss standard
AWWA American Water Works Association.
3.1.1.4 Conflicting Requirements, Exceptions
The Pipe Coating Contractor shall notify the Engineer of any conflict between
this specification, the codes and standards and any other specifications
included as part of the contract documents related with line pipes and coating.
Any exceptions to this specification and referenced documentation shall be

raised by the Pipe Coating Contractor and approved by the Engineer in
writing.
3.1.2 TECHNICAL REQUIREMENTS
3.1.2.1 HANDLING OF COATING MATERIALS
3.1.2.1.1 General
Materials shall be brought from the GWSSB approved vendor list only and
shall be handled and stored in accordance with the material manufacture’s
recommendations, which shall be available for review by the Engineer at the
Pipe Coating Contractor’s premises. Materials shall be stored in temperature
controlled environment until required for use.
Coating materials shall be segregated by type and batch during storage and
handling. Materials from damaged containers shall be rejected unless
otherwise agreed with the Engineer.
As a minimum, all packages of the coating materials shall be marked with the
following data:
a) Name of manufacturer
b) Complete material identification – trade name, chemical name
and
c) type of product details
d) Batch number
e) Date of manufacture
f) Place of manufacture
g) Shelf life/expiry date (if appropriate)
h) Health and safety, and environmental instructions
i) Hazard Warnings
j) Storage instructions
k) Quantity
l) Manufacturing Standard
Any material not labeled with the above information shall not be used
GWSSB 80
3.1.2.1.2 Abrasive Grit
The abrasive shall be steel grit, also in combination with steel shot of the
required grade to achieve the specified surface profile. The use of sand is not
permitted.
Blasting abrasives shall be kept dry, clean and free from contamination. When
recovered metallic grit systems are used, a stabilized working mix of blast
cleaning material shall be established. This mix shall be maintained throughout
the entire course of the production, by frequent small additions from fresh or
cleaned stock at a rate sufficient to refurnish consumption. Blasting and other
dust producing areas shall be kept separate from coating application areas. The
surface cleaning shall be degree of cleanliness as per SA 21/2 & ISO 8502-3.
3.1.2.1.3 FBE Powder
The FBE powder selected shall be suitable for use at the design temperatures
in the proposed environment and be suitable for a three layer polyethylene
coating system. The FBE shall be endorsed by the Pipe Coating contractor of
the adhesive and Polyethylene as being compatible with these products under
the specified service conditions.
Each batch of FBE shall be accompanied by a certificate stating the following

tests have been carried out on every batch and results are in accordance with
the coating material manufacturer’s product specifications;
 Gel Time
 Moisture content
 Particle size distribution
 Density
 Infrared Scan
 Thermal analysis
3.1.2.1.4 Adhesive
The adhesive selected shall be completely suitable for use at the design
temperatures in the proposed environment and be suitable for a three layer
polyethylene coating system.
Each batch of adhesive shall be accompanied by a certificate stating the

following tests have been carried out on every batch and results are in
accordance with the coating material manufacturer’s product specifications:
 Adhesion
 Density
 Melt flow index
GWSSB 81
3.1.2.1.5 Polyethylene
The polyethylene selected shall be or high density and shall be completely

suitable for use at the design temperatures in the described environment. The
polyethylene shall be suitable for a three-layer polyethylene can be stabilized
against UV-rays before or after granulating the material
Each polyethylene batch shall be accompanied by a certificate stating the

following tests have been carried out on every batch and results are in
accordance with the coating material manufacturer’s product specification:
3.1.2.1.6 PROPERTOES OF EPOXY POWDER & ADHESIVE
3.1.2.1.6.1 MANUFACTURER shall choose such a brand of epoxy powder and adhesive
that will achieve the functional requirement and properties of coating system as
specifiedand shall submit a compatibility certificate in this regard from the
manufacturer of materials. In absence of such certificate, compatibility test shall
be conducted by the contractor by contractor at his own cost. In addition, the
Manufacturer shall also furnish Infra-red Scan for each batch of epoxy powder.
The coating materials Supplier shall issue test certificates as per EN 10204 for
each batch of materials supplied to MANUFACTURER and the same shall be
submitted to PURCHASER for approval prior to their use. Epoxy powder
properties shall be as per CSA Z245.20.98 (latest revision). The colour of epoxy
powder shall be either green or dark red or any other colour approved by
COMPANY except grey colour. Copolymer grafted adhesive shall have the
following properties.
Sr.No. Properties Unit Requirement Test Method
a. Melt Flow Rate (1900C/216 g/10 minutes 1.0 min ASTM D 1238
kg)
0
b. Vicat Softening Point C 100 min ASTM D 1525
c. Specific Gravity - 0.926 min ASTM D 792
3.1.2.1.6.2 Properties of Polyethylene Compound
a. Tensile Strength @ + 25 0C N/mm2 17 min ASTM D638
b. Melt Flow Rate (1900C / 2.16 g/10 0.25 ASTM D 1238

kg) minutes or DIN 53735
c. Specific Gravity + 250C - 0.926 min. (MDPE) ASTM D 792
0.941 min.(HDPE)
GWSSB 82
d. Hardness @ + 250C Shore D 50 min. ASTM D 2240
e. Water Absorptions, 24 hours % 0.05 mz. ASTM D 570

@ + 250C
f. Volume Resisitivity @ + 25 Ohm-cm 1015 min. ASTM D 257

0
C
g. Dielectric withstand, 1000 Volts/mm 30,000 min. ASTM D 149

Volt/sec rise @ + 250C
0
h. Vicat Softening Point C 110 min. ASTM D 1525
i. Elongation % 600 min. ASTM D 638
j. Oxidative Induction Time in Minutes 10 min. ASTM D 3895

Oxygen at 2200C, Aluminum
pan, no screen
k. Environmental Stress Crack Hours ASTM D 1693

Resistance (ESCR) (for F50)
- Medium Density , Condition

"C" 300
- High Density, Condition "B"

300
l. Carbon Black Content % 2 min. ASTM D 1603
3.1.2.1.6.3 In addition to vendor’s certificate, the MANFUCTURER shall draw samples

from each batch of epoxy, adhesive and polyethylene in the presence of
PURCHASER and the test for the following properties at the coating yard at
least one week prior to its use, to establish compliance with the Manufacturer’s
test certificates.
(A) Epoxy Powder: Gel Time, Cure Time, Moisture content, Thermal
Characteristics (Tg1, Tg2, ∆H)
(B) Adhesive: Specific gravity, Melt Flow Rate, Vicat Softening Point
(C) Polyethylene: Melt Flow Rat, Specific Gravity, Vicat Softening Point,
Moisture content, Oxidative Induction Time.
In Case of the failure of any of the above tests in a batch, that batch of
material shall be tested for all other tests required including the tests which
failed. If all tests pass, the batch shall be accepted for coating. If any of the
GWSSB 83
tests fail, entire batch of material shall be rejected and shall not be used for
the coating.
3.1.2.1.6.4 MANFUCATURER shall ensure that all coating materials are properly stored in
accordance with the Manufacturer’s recommendation at all times, to prevent
damage and deterioration in quality prior to use.
3.1.2.1.6.5 Properties of coating System
a. Bond Strength (using Type 2 Kg/cm DIN 30670

test assembly i.e.
Dynamomometer)
- @ 20+ /- 50C
- @ 65 +/- 50C 8.0 min
5.0 min
b. Impact Strength (Mon. of 30 Joules per mm 7 min DIN 30670

impacts on body along the of coating
length. No breakdown thickness
allowed when tested at 25
Kv)
c. Indentation Hardness mm DIN 30670
- @ 23 +/- 20C 0.2 max

- @ 70 +/- 20C
0.3 max
d. Elongation at Failure % 300 min DIN 30670
e. Coating Resistivity (*) Ohm-m2 108 min. DIN 30670
f. Heat Ageing (*) - Melt Flow rate DIN 30670

shall not
g. Light Ageing (*) - deviate by DIN 30670
more than 35%
of original value
Melt flow rate
shall not
deviate by
more than 35%
of original
value.
GWSSB 84
h. CathodicDisbondment Minimum radius 15 max ASTM G42

of disbondment
- @ + 650C after 30 (**) 7 max
days
- @ + 650C after 48
hrs
i. Degree of Cure of Epoxy CSA Z 245.20

– 98 (***)
- Percentage Cure, ∆H % 95
- ∆Tg 0
C +3/-2
(*) Test carried out in an independent laboratory of national / international recognition of

PE top coat is also acceptable.
(**) Disbondment shall be equivalent circle radius of total unsealed area as per ASTM G
42.
(***) Temperature to which the test specimens are to be heated during cyclic heating shall
however be as per the recommendations of epoxy powder manufacturer.
3.1.2.2 Acceptance of Pipe Materials
Identification and Tracking
Upon receipt at the coating factory, the Pipe Coating Contractor shall record the
following pipe information:
The unique pipe identification number, measured length, and measured weight
(both to be found stenciled in paint on one end or the pipe).
This data shall be used as a basis for monitoring pipe from the time of receipt until
the delivery of coated pipe.
The Pipe Coating Contractor shall identify (or maintain identification of) every
coated item, by using a weatherproof mark on the inside of the pipe and on the
outside of the coated item. The pipe identification shall be the unique pipe
identification number (the number required by the applicable pipes specification).
The pipe coating contractor may use additional tracking numbers at his discretion
but these shall relate simply to the unique pipe number in the QC documentation.
Pipe tracking shall be carried out in accordance with approved procedures.
GWSSB 85
3.1.2.2.1 Preliminary Inspection
The Pipe Coating Contractor shall carry out visual inspection of all pipes.
The Pipe Coating Contractor shall record all external damage on pipes against the
unique item serial number. This damage shall be brought to the attention of the
Engineer and the Pipe shall not be coated without prior release by Engineer.
Bevel protectors at each end of every pipe joint shall not be removed unless
showing signs of damage or if removal is required to facilitate surface preparation,
or they would be damaged by coating operations. If the protectors are removed the
conditions of the bevel shall be recorded against the pipe serial number and any
damage shall be brought to the attention of the Engineer.
3.1.2.2.2 Damage to Pipe and Pipe Ends and Repair
No repair work shall proceed until a written procedure has been prepared by the
Pipe Coating Contractor and approved by the Engineer.
Minor damage to pipe and pipe ends/bevels, identified either at time of receipt or
after abrasive blasting shall be repaired by grinding. The number of such damages
shall be not more than 3 per pipe. Repair by grinding on the pipe or pipe ends/
bevels outside diameter shall not reduce the wall thickness to less than the
minimum requirements of the line pipe specification, when measured using
ultrasonic thickness measurement equipment.
All other damage to pipe ends/bevels shall be advised to the Engineer for review.
Subject to Engineer’s approval, these defects may be repaired by removal of
damaged pipe material and re-beveling. No welding on the pipe surface shall be
allowed.
Pipe identification numbers shall be preserved during repair. Any reduction in pipe
lengths shall be recorded in the relevant forms and files.
3.1.2.3 Prior to Coating Application
Stages
The principle stages of pipe coating shall be as follows:
 Solvent cleaning followed by steam or hot bath cleaning (if required)

 Abrasive blasting
 Application of fusion bond epoxy (FBE) layer
 Application of adhesive layer
 Application of polyethylene layer
GWSSB 86
Cleaning Prior to Abrasive Blasting
All surface contaminants such as oil, grease, tar, salt, or other contaminants on the
pipe shall be removed by solvent cleaning followed by steam or hot bath cleaning,
in accordance with a procedure approved by the Engineer.
Following the steam or hot bath cleaning the pipe shall be tested for salt and
chloride contamination in accordance with the requirements of DIN EN ISO 8502-2,
ISO 8502-5 or DIN EN ISO 8502-9.
The removal of hydrocarbon contamination shall be confirmed by a water spray

test, where a fine spray is applied to the surface and uniform wetting confirms the
removal. This check shall be performed before and after blasting, as a pre-
qualification test and as a minimum, once per 100 items during production, or when
necessary.
Items found to be contaminated shall be cleaned as above and re-blasted if testing

after blasting establishes that salt, chloride or hydrocarbon contamination is still
present. The remainder of the batch concerned shall all be checked individually.
All water used for rinsing or cleaning purposes shall be potable with less than 200
ppm total dissolved solids and 50 ppm chlorides.
Abrasive Blasting
Blasting and other dust producing areas shall be separate from coating application
areas.
After cleaning and prior to abrasive blasting the pipe lengths shall be free from
moisture, dust, and grease and free from other foreign materials.
Abrasive and dust, which entered the inside of the pipe during blasting operation,
shall be removed by suitable means.
Wield joints, sharp-edge projections; weld spatter and slag etc. shall be dressed
prior to blast cleaning.
Using dry blasting techniques only, the exterior surface of the pipe joints shall be
abrasively cleaned to remove all mill scale, and other impurities from the surface.
No blast cleaning shall take place when the prevailing relative humidity is higher
than 85 percent unless pipe is preheated to at least 3º C above the dew point.
Twice per shift, samples of the abrasives mixture shall be removed from the hopper
and checked for hydrocarbon contamination. The sample shall be placed in a
beaker to which de-ionized water is added. The beaker shall then be sealed and
shaken vigorously. Once the grit has settled the surface of the water shall be
examined for signs of hydrocarbon contamination. If any signs are found all the
abrasive in the hopper shall be rejected and not re-used.
GWSSB 87
Additionally, abrasive materials shall be checked at least once per shift to ensure
that only uncontaminated angular grit with an acceptable size distribution is used.
As a minimum the following shall be carried out.
 Correct abrasive size distribution shall be carried out by sieve analysis.

 Placing a sample of abrasive on a clean, dry sheet of absorbent paper to
determine water contamination.
The surface of the pipes shall be blasted until a finish of Grade 2.5 to DIN EN ISO
8501-1 is attained. The surface profile shall be between 50 to 75 microns,
measured in accordance with DIN EN ISO 8503-2. Profile measurements shall be
made with a Keane Tator Profile Comparator, Testex Press –O-Film or other
Engineer approved method suitable for the abrasive being used.
Following abrasive blasting, the surface shall not be contaminated with dirt, dust,
metal particles, hydrocarbons, water, chlorides, sulphates or any other foreign
matter, which would be detrimental to the coating.
Prior to the coating application, the exterior surface shall be thoroughly inspected
under adequate lighting. Any damage such as surface imperfections, slivers,
scabs, burrs, gouges, or sharp edged defects, shall be repaired in accordance with
this specification. Pipes that have damage repaired by grinding and have ground
areas greater than 50 mm diameter shall be re-blasted to meet the requirements.
After grinding or mechanical repairs the wall thickness shall be ultrasonically
examined and compared with the minimum requirements of the applicable code /
standard.
Any dust or loose residue that has accumulated during blasting and/ or grinding
operations shall be removed by the use of clean compressed air or by vacuum
extraction. Alternative methods for removing dust and lint shall require approval of
the Engineer.
The elapsed time between the start of blasting and the heating of pipe shall be
indicated in the application procedure submitted by the Pipe Coating Contractor
and shall be reflected on his plant scheme.
The total elapsed time between the start of blasting of any pipe and the heating of
that pipe to the specified temperature shall not exceed the following time-humidity
table:
PERCENT RELATIVE ELAPSED TIME (HOURS)
HUMIDITY
85 0.5
80 1.0
70 2.0
60 2.0
GWSSB 88
Any pipe surface not processed within the above time-humidity table shall becompletely re-
cleaned and re-blasted before coating. The maximum time limit between blasting and
coating for humidity below 60% shall be 4 hours.
Note : The Method of Blasting will be finalized at the time of execution based on site
condition.
Coating Application
General
The application of the coating shall be in accordance with the material manufacturer
recommendations and the procedure outlined below.
The Pipe Coating Contractor shall perform coating procedure qualification testing
(PQT) prior to commencing production or on his own risk at the start of production in
accordance with this specification.
Prior to start up of the coating process the powder application and recovery systems
shall be thoroughly cleaned to remove any powder other than that is use, minimum
once per day and the collected powder shall be disposed off.
FBE Layer
The FBE shall be applied to a minimum thickness of 200 microns.
The pipe shall be uniformly preheated in accordance with the FBE manufacturer’s
instructions. This temperature shall have been confirmed during PQT. The surface
temperature shall not exceed 260 deg C in accordance with AWWA C213.
Pipe temperature shall be checked periodically using pyrometer. The pyrometer shall
be checked for error not less than every four hours against a calibrated temperature
measuring instrument.
The coating shall be applied by electrostatic spray with the pipe at earth potential and
the epoxy powder charged to high potential.
The use of reclaimed FBE powder is only permitted if the reclaimed powder is
screened to remove foreign or deleterious material before being reintroduced into the
powder application system.
The clean reclaimed powder up to a maximum of 20% shall be introduced back into
the fresh virgin material by means of proportional weight.
During application, the beveled ends and pipe bore shall be protected against
mechanical damage and from contamination with coating material.
GWSSB 89
Adhesive Layer
The adhesive shall be applied to a thickness of 200 microns.
The adhesive layer shall be applied before gel time of the FBE has expired.
Application of the adhesive shall not be permitted after the FBE has fully cured. The
Pipe Coating Contractor shall establish to the satisfaction of the Engineer that the
adhesive is applied within gel time window of the FBE and at the temperature
recommended by the adhesive manufacturer. The Pipe Coating Contractor shall
state the proposed minimum and maximum time interval between FBE and adhesive
applications at the proposed pre-heat temperature.
Polyethylene Layer/Cutback
The polyethylene layer shall be applied to a minimum thickness as per DIN 30670
over the pipe body and to a minimum of 90% body thickness over the production
welds.
Minimum Thickness in mm
Nominal Size
Normal (n) Increased (v)
≤ DN 100 1.8 2.5
> DN 100 to ≤ DN 250 2.0 2.7
> DN 250 to < DN 500 2.2 2.9
≥ DN 500 to < DN 800 2.5 3.2
≥ DN 800 3.0 3.7
A polyethylene layer cutback of 150 mm (+10/-10mm) shall be provided at pipe ends.
The polyethylene shall be applied over the adhesive within the time limits established
during pre-production testing.
The coating shall be cooled to below 60 deg C before handling.
The ends of the coating shall be chamfered and beveled to 30 to 45 deg
Immediately after the coating is fully cured, pipe identification marks shall be re-
applied o the coated pipe using a method approved by Engineer.
GWSSB 90
INSPECTION, TESTING AND CERTIFICATION
GENERAL
In order to demonstrate that the manufacturer’s proposed coating procedure is

capable of meeting the specification, the Pipe Coating Contractor shall undertake
coating procedure qualification testing (PQT) prior to commencing production, or at
his own risk at the start of production. The pipe coating Contractor shall also be
required to test the finished coating during production to demonstrate continued
compliance with this specification. Details of all inspections and testing shall be fully
documented in accordance with this section.
All states of the surface preparation, coating and testing shall be subject to 100%
inspection by the Pipe Coating Contractor. The Engineer shall be informed at least
two weeks prior to the start of surface preparation to allow scheduling of inspection
supervision work
Coating Procedure Qualification Testing (PQT)
Prior to commencing or at the start of full production five pipe joints of each diameter
coated with FBE only and five pipe joints of each diameter with the full coating
system shall be selected for PQT. All coating shall be in accordance with the coating
procedure specifications and shall be witnessed by the Engineer or its
representative.
The produced pipes will not be released until the successful results of the PQT can
be provided. In case of long-term tests the PQT report shall be updated once the
results can be provided. Any failure in meeting the specified acceptance criteria for
the PQT will result in rejection of the coated pipes. Engineer shall approve any
remedial action, repairs or re-use.
The test methods for all tests required for PQT on the FBE and the complete coating
system shall be performed in the same manner as the production tests described in
this specification.
Pipes selected for PQT testing shall pass all the criteria containing before production
commences.
Any change in the coating material or coating procedure shall require re-qualification.
If any of the tests fails to meet the minimum acceptance criteria defined in this
specification, then the pre-qualification pies shall be rejected. Further pipes may be
prepared and coated using revised procedures and further tests performed. Once
acceptable results are obtained and approved by Engineer, the Pipe Coating
Contractor’s quality plan and procedures shall be revised, and submitted to the
GWSSB 91
Engineer for approval. All items coated using the rejected procedures shall be striped
and recoated to the revised procedures.
PQT Inspection and Test Summary
Inspection and testing summary for procedure qualification test (PQT) for three layer
coating system for each pipe diameter:
Property Acceptable Values Frequency of

Tests
On Arrival
 Pipe Damage Minor damage/grinding <3 Each Pipe

Per Pipe
After Cleaning
Chloride 2 mg/cm2 Each Pipe
Oil No contamination
Salt 3 mg/cm2
After Abrasive Blasting
 Cleanliness Sa 2.5 acc to ISO 8501 Each Pipe

 Profile
 Contamination 50 – 75µm Each Pipe
No contamination Each Pipe
property Acceptable Values Frequency of Tests
 Visual Inspection No surface defects Each Pipe

 Holidays
 Thickness No holidays Each Pipe
 Adhesion
Min/Max see as specified 10 per pipe
As specified 2 per pipe
Holidays
Visual Inspection No surface defects Each Pipe
Coating 120+10/-0 mm width Each Pipe
Bare steel at pipe ends 10 to 40 mm width, Each Pipe
Production FBE Chamfered Each Pipe
PE cut backs 150 + 10/-10 mm bevel 300
GWSSB 92
to 450
Adhesion
 Peel Test > 100 N/cm at 230 C ±50 2 per Pipe
> 50 N/cm at 500 C ±50 2 per Pipe
Impact Resistance As specified 1 per pipe
% Elongation at Failure As specified 2 per pipe
Cathodicdisbondment As specified 2 per pipe
DIN 30670 As specified 1 per pipe
PRODUCTION TESTING
Production testing shall be performed at the frequency shown below:
property Acceptable Values Frequency of

Tests
On Arrival
 Pipe Damage Minor damage/grinding <3 Each Pipe

Per Pipe
After Cleaning
Chloride 2 mg/cm2 Each Pipe
Oil No contamination
Salt 3 mg/cm2
After Abrasive Blasting
Cleanliness ISO-Sa Each Pipe 20
Profile 50 – 75µm Each Pipe 20
Contamination No contamination
Pipe Damage As specified
FBE Layer One pipe per day

and one pipe when
 Visual Inspection
GWSSB 93
 Holidays No surface defects FBE batch changes

 Thickness
 Adhesion No holidays
Min/Max see As specified
As specified
Coating Thickness As specified Each Pipe
(minimum)
Holidays No holidays Each Pipe
Visual Inspection
Coating No surface defects Each Pipe
Bare steel at pipe ends 120+10/-0 mm width Each Pipe
Production FBE 10 to 40 mm width, Each Pipe
PE cut backs Chamfered Each Pipe
150 + 10/-10 mm bevel 300

to 450
Adhesion
Peel Test > 100 N/cm at 230 C +50 1 Pipe per 25
2 per Pipe
CathodicDisbondment As specified First pipe, last pipe

and at intervals of
at Room Temperature every 500 pipes
The frequency of tests shown in the table above will be for normal production
operations. This frequency of tests is subject to change at the discretion of the
Engineer as a result of change of materials or consistent poor production
performance.
GWSSB 94
HOLIDAY DETECTION
FBE Layer:
The FBE coating shall be 100 % holiday tested with a pulse type DC holiday detector
equipped with audible signaling device. The test shall be carried out in accordance
with NACE RP0490 or equivalent.
Final Coating:
Each fully coated pipe shall be inspected for holidays over 100 percent of its coated
surface using a high voltage DC detector.
The detector shall be a type, which maintains complete contact with the coating. It
may be either constant or pulsed voltage type. If constant voltage type, holiday
detection shall be carried out on a dry coating. The operating voltage between
electrode and pipe shall be checked at least twice per working shift, and shall be
maintained at 10 kilovolt/mm of coating thickness.
The Pipe Coating Contractor shall demonstrate to the Engineer that the setting of the
detector is satisfactory for detecting pinhole defects. This setting shall be checked
once every two hours. The correct travel speed shall be determined by consistent
detection of an artificial pinhole made in a good coating sample but shall not exceed
300 mm/s.
All holidays and other detects shall be marked for subsequent repair and re-testing.
On retesting, no holidays shall be permitted in the final coating.
The number of holidays for each pipe length shall be recorded. Coated pipe having
holidays in excess of 1 per 1 square meter shall be stripped and re-coated.
If there is an excess occurrence of holidays on successive pipes, the Pipe Coating

Contractor shall immediately stop the coating operation to determine the cause and
remedy it.
ADHESION (PEEL) TSET
FBE Layer:
With a sharp narrow bladed knife, two incisions (approximately 13 mm long) shall be
made, in the form of an X. through to the metal substrate. At the intersection of the
X. an attempt shall be made to force the lining from the steel substrate with the knife
point. The point of the knife shall be inserted horizontally i,e., the flat of the blade
under the lining at the point of intersection of the X such that the blade point is on the
metal surface. Using a levering action, the flat point shall be forced away from the
steel in an attempt to pry off the coating. Refusal of the lining to disbond from the
substrate shall be recorded as a pass. A pass shall also be recorded where the lining
fails cohesively. Partial or complete adhesive failure between the lining and the
GWSSB 95
substrate shall be recorded as a failure. Disbondment at the point of the intersection

is common due to the action of marking the 'X' cut. Therefore for 1 mm away from the
tip of the intersection any disbandment shall be ignored.
Final Coating:
The adhesion for the complete coating shall be determined in accordance with the
requirements for bond strength in DIN 30670. The relevant test temperature and
acceptance criteria for these tests shall be as specified. Automatic chart recording
equipment shall be used and the average peeling force shall be recorded.
The failure mode shall be recorded. The failure should occur at the
adhesive/polyethylene interface or adhesive/FBE interface or cohesively in the
polyethylene layer. If failure should occur at the FBE/steel interface this will be
considered a total failure of the system.
Impact Test
A sample or coated pipe shall be impact tested in accordance with the procedures
and acceptance criteria of DIN 30670.
Resistance to Indentation Test (Indentation Hardness)
Once per shift (and when the FBE or polyethylene batch is changed), the indentation
hardness of two coated samples shall be measured (at 23○C ± 5○C and 70○C ± 2○C)
in accordance with DIN 30670
Indentation depth shall not exceed 0.2mm at 23○C ± 5○C or 0.3mm at 70○C ± 2○C.
Percentage Elongation at Failure
This test shall be conducted in accordance with DIN 30670 on each of the full system
pre-qualification pipes, but at least the coating of three pipes shall be tested for
elongation at failure, from which five test pieces shall be taken. The percentage
elongation at failure shall be at least 300% - on each of the full system pre-
qualification pipes, 2 samples per pipe to the requirements of DIN 30670.
Other DIN 30670 Tests
The Pipe Coating Contractor shall demonstrate, for the same system to be applied
for this order, attainment of DIN 30670 requirements for Coating Resistivity, to
Thermal Ageing and Light Ageing as required by DIN 30670. .
GWSSB 96
CATHODIC DISBONDMENT TEST
CathodicDisbondment testing shell be conducted:
as a pre-qualification test - 48 hours duration at 65 +/- 2○C
as a pre-qualification test - 28 days duration at 23 +/- 2○C
as a production test - 48 hours duration, at the frequency of one test per 50D coated
pipes at 65 +/- 2○C
The test requirements shall be in accordance with ASTM G 8.
The final unsealed diameter (including the initial holiday diameter of 6.35 mm) shall
not exceed 15 mm. This shall apply to both, the 28 day test at 23 +/- 2 ○C and the 2
days test at 65 +/- 2○C.
The Pipe Coating Contractor may propose alternative cathodicdisbondment test

standards provided the essential requirements of this specification are retained. Any
such alternatives shall be submitted to the Engineer for review and approval.
Every 24 hours the applied voltage and current flow shall be recorded. Any drift from
the specified voltage setting shall be corrected.
DESTRUCTIVE TEST
A sufficient length of production pipe shall be cold cut to provide the required number
of samples for conducting the coating destructive tests listed in this specification.
Items that fail individual tests and that cannot be repaired shall be rejected. Subject
to the approval of Engineer, the rejected coating shall be stripped and the joint shall
be re-blasted and coated in the manner specified for new pipe in this specification.
Where a test relates to a quantity of coated items, e.g. 1 per 50 items or 1 per 100
items etc., the quantity or items represented by the item tested (e.g. 50 or 100) shall
be considered to be a batch.
If a test on an item in a batch fails then this item shall be rejected and two further
items shall be randomly selected from the batch for repeat testing. If either of these
tests fails then the whole batch shall be quarantined for review by Engineer. The
cause of failure shall be established and reported to the Engineer and if deemed
necessary by the Engineer the coating procedure shall be amended and re-qualified.
The Engineer will decide whether the whole batch is rejected and sent for re-blasting
and re-coating or whether acceptance may be on the basis of acceptable tests
carried out on individual items.
GWSSB 97
COATING REPAIRS
The Pipe Coating Contractor shall submit detailed coating repair procedures for
approval by Engineer. These shall include procedures for repair or 'pin-hole', 'small
area' and 'large area' defects. The minimum and maximum areas for which each type
of repair is applicable shall be stated taking into consideration the below mentioned
requirements.
The maximum number of coating defects allowable, before a joint of pipe shall be
classed as rejected and recoated, shall not exceed 1 per 1 square meter (exclusive
of damage caused by testing).
 Repair areas of sizes < 5 mm2
Pinhole damage shall be repaired by cleaning with an emery cloth

followed by application of a two (2) pack epoxy repay repair kit or an
approved hot melt mastic smoothed flush with the polyethylene
surface. If the mastic is used, it shall be spread with the aid of a hot air
or a propane torch.
 Repair areas of sizes > 5 mm2 up to < 250 mm 2
The area shall be cleaned with solvent and abraided with an emery
cloth to ensure that the surrounding polyethylene is well bonded, the
surface shall be roughened for a distance of at least 25 mm beyond
the damage area. Approved hot melt mastic shall be applied to the
damage area and smoothed flush. The mastic and surrounding area
shall be warmed with hot air or propane torch until the surrounding
polyethylene has as slight sheen. An approved polyethylene patch
material shall be applied overlapping the damage but not overlapping
the pre-abraided areas. Torch heat and smoothing pressure shall be
applied to fuse the patch and ensure that no blisters are formed.
 Repair areas of sizes 250 mm2 up to 625 mm 2
Heat shrink-wrapping pipe sleeves shall be used for repair according

to the following procedure:
Thoroughly clean the area to be coated
Bevel the extremities of the mill-coating with a rasp
Pre-heat the area to be coated to a temperature of approximately 700C.
Install the sleeve over the area to be coated
GWSSB 98
Warm the shrink sleeve to a temperature above 150OC with a propane

torch or a warm-air ring.
 Repair areas of sizes exceeding 625 mm2
No single defect shall exceed an area or 625 mm2. Pipes with a

coating defect exceeding 625 mm 2 shall be cause for rejection and
shall be subsequently rejections and recoated. All rejections shall be
recorded.
Repairs shall provide a finished coating equal in effectiveness to that of the

parent coating. The limit of the repair area shall be revised.
Each repaired area shall be holiday inspected in accordance as specified.
The Pipe Coating Contractor shall submit coating stripping procedure for
pipes rejected for coating quality. The rejected coating may be stripped by
heating in an oven. Under these circumstances, the temperature of the pipe
joint shall not be allowed to rise above 400 0C.
HANDLING, TRANSPORT AND STORAGE

The Manufacture shall be responsible for any damage occurring to the pipes
from unloading to reloading on the relevant transportation means.
The Manufacturer shall consequently:
- inspect the bare pipes upon delivery to check that they have suffered no
previous damage,
- take all necessary precautionary measures to prevent any deterioration

during the following operations:
- handling,
- transfer tot storage yards.
- storage,
- loading of pipes for shipment.
All repairs and inspections shall be at the Manufacturer's expense.
Handling
The pipes shall b e handled without causing damage to the pipe bevels and
coating.
Direct contact steel or hamp slings or with any material whose shape or
nature may deteriorate the pipe coating shall be strictly prohibited. Polyamide
slings or hooks fitted with thermoplastic protection may be used.
GWSSB 99
Use of electromagnetic device is recommended.
Transfer to Storage Yard
During transport of pies to the storage yard of the Manufacturer, the latter
shall take all their required measures to avoid pipe and coating damage.
Storage Yard of the Manufacturer
Stockpiling of coated pipes shall be made so as to avoid any deterioration of

coating. Coated pipes, when non concrete weight coated, shall be protected
against ultraviolet rays action in particular.
Pipe Loading for Shipment
When loading the coated pipes for shipment, the Manufacturer shall take all
necessary measures to avoid the deterioration of pipes and coating during
handling and transport.
End Caps
If the bare pipes have been delivered to the Manufacturer with end caps,
these end caps or new ones) should be fitted again on the pipe ends after
coating if required in the CONTRACT.
REPAIR OF COATING
MANUFACTURER shall submit to PURCHASER, its methods and materials

proposed to be sued for executing a coating repair and shall receive approval
from PURCHASER prior to use. In open storage the repair materials must be
able to withstand a temperature of at least (+) 800C without impairing its
serviceability and properties. MANUFACTURER shall furnish manufacturer's
test certificates for the repair materials clearly establishing the compliance of
the repair materials with the applicable coating requirements indicated in this
specification.
All repair material will be of Class C.70 as specified in the relevant DIN
Standard.
GWSSB 100
All pipe coating plan, shall have sound external with no holiday or porosity on
100% of the surface.
Defects, repairs and acceptability criteria shall be as follows:
- Pipes showing porosities or very small damage not picked up

during holiday test and having a surface less than 0.5 cm 2 or
linear damage (cut) of less than 3 mm shall be repaired by stick using
material of same quality.
- Damages caused to coating by handling such as scratches,

cuts, dents, gouges, not picked up during holiday test, having a
total reduced thickness on damaged portion not less than 2 mm and an area
not exceeding 20cm 2 shall be rebuild as per approved method and without
exposing to bare metal.
- Defects of size exceeding the above and mentioned area of or

holidays of width less than 300 mm shall be repaired as per
approved method by exposing the bare metal surface.
- Defect exceeding the above and in number not exceeding 2 per pipe
and their length not exceeding 500 mm shall be repaired as per approved
method.
- Pipes with bigger damage shall be stripped and recoated.
- In case of coating defect close to coating cut back,

MANUFACUTRER shall remove the coating throughout the entire
circumference of the pipe down to the steel surface and increase the
coating cut back length. Now, if the coating cut back exceeds by 30 mm
than the specified cut back length, then the coating shall be repaired as per
approved method thereby making up the coating cut back length as per
specification.
In case the defect exceeds 70 mm from the original coating cut back length,
the entire coating shall be removed and the pipe shall be recycled through the
entire coating procedure.
Irrespective of type of repair, the maximum number of repair of coating shall

be as follows:
- Holiday repair of size ≤ 100 cm2attributable to process of coating

application shall be maximum one number per pipe.
- In addition to the above, defects to be repaired as per approved

method shall be maximum 2 (two) per pipe.
GWSSB 101
Defects exceeding the above limits shall cause pipe coating rejection,
stripping and recoating. The above is exclusive of the repairs warranted due
to testing as this specification.
All repairs carried out to the coating for whatever reason shall be to the
account to MANUFACTURER.
Cosmetic damages occurring in the polyethylene layer only need not be

repaired by exposing up to steel surface, as deemed fit by the PURCHASER.
In any case the MANUFACTURER shall establish his material, methods and
procedure of repair that result in an acceptable quality of product by testing
and shall receive approval from PURCHASER prior to use.
Testing of repairs shall be in the same form as testing coating. All repairs
shall result in a coating thickness no less than the parent coating thickness.
MANUFACURTRER shall test repairs to coating as and when required as and
when required by PURCHASER.
Repair Material : Heat Shrink Sleeves
HTPL-80, PERP 80 PERP FILLER, S 1239 Epoxy or Canusa GTS-

80, CRP 80 Mastic Filler, S/E/liquid epoxy and then should be
followed by or equivalent material to be qualified by the material
manufacturer and approved by Purchaser.
 Any combination of epoxy, adhesive and polyethylene shall be tested and certified by
an internationally recognized agency.
 In case the MANGUACTURER proposed coating material other than above e

mentioned combination of epoxy, adhesive and polyethylene, coating procedure and
qualification need to be carried out by an internationally recognized agency by the
coating material Manufacturer.
 All materials to be used shall be supplied in sealed, damage free containers and shall
be suitable marked with the following minimum information:
a) Name of the Manufacturer
b) Type of Materials
c) Batch Number
d) Place and Date of Manufacture
e) Shelf Life/Expiry Date (if Applicable)
f) Quantity
GWSSB 102
All materials noted to be without above identification shall be deemed suspect and
shall be rejected by PURCHASER. Such materials shall not be used for coating and shall be
removed from site and replaced by MANUFACTURER at his expense.
GWSSB 103
LOFC : LIST OF OPERAION OF FABRICATION AND CONTROL
Each LOFC must contain the following information as a minimum (all clearly marked and
separated):
a) Company name and references relating to the order;
b) All technical and other information required in order to define the items covered.
 The area of application will be limited to that item or those items considered in
fabrication and control as a natural unity.
 Details of plants, layout, capacity, production rate, testing equipment, yard facility
c) A numerical sequence of operations with description will be built-up in a logical way
of work progress.
 The first operation will be the control over the incoming material(s) and documents.
 The last operation will be the control over the final documentation.
The following operations have to be included (not limited to):
 Procedure prior to the commencement of production shall be approved by

PURCHASER
 Each step which call for own quality control (eventually QA);
 Each applicable examination as part of this specification;
 Document control-stamping and final documentation.
d) Each operation will be followed by the applicable specification or procedure number

(with the latest revision).
e) Columns to be provided for possible interventions of :
the manufacture's fabrication control;
the manufacturer's quality control (eventually QA);
inspection Agency;
and place of intervention if not by the manufacturer.
The interventions will be indicated per operations with H or w and/or R.
H= hold point - no further steps may be undertaken before the intervention of the
designated responsible takes place.
W= witness point - the designated responsible has to be notified of the operation in

advance, but production will continue whether the intervention took place or not.
GWSSB 104
R= point for which a control report or a recording has to be made.
The manufacturer will rill in his own H, W and R points. The inspection Agency will do the
same in its designated column, but this will not implicate a relaxation or wearing of the
requirements of the manufacturer's controls.
Each intervention has to be signed and dated by person acting as controller. Only the
original documents will be presented for this purpose.
f) One column to be provided for report or record number (point marked R) and one
for the review or these documents by the Inspection Agency.
g) Two extra columns may give reference to non-conformity report if any and to
the resolution give to it.
Completion of the LOFC does not automatically rise to a release o the material or it must be
stipulated otherwise in the contract.
The steps indicated in the LOFC must be executed following the sequence as stipulated in
LOFC.
Coating of field joint
SCOPE
This specification establishes the minimum requirements of materials, equipment and
Installation of field joint anti-corrosion coating of buried onshore pipelines factory coated
withthree-layer polyethylene coating, by heat shrink wraparound sleeves conforming to
EN 12068.
– “Cathodic Protection – External Organic Coatings for the Corrosion Protection of

Buried orImmersed Steel Pipelines used in Conjunction with Cathodic Protection –
Tapes andShrinkable Materials” and the requirements of this specification. Unless
modified/replaced bythis specification, all the requirements of EN 12068 shall remain
fully applicable and compliedwith.
This specification shall be read in conjunction with the conditions of all specifications
anddocuments included in the Contract between Company and Contractor. Unless
specifiedotherwise, all sections of this specification shall apply to all specifications
referred in thisspecification.
GWSSB 105
REFERENCE DOCUMENTS
Reference has also been made to the latest edition (edition enforce at the time of issue
ofenquiry) of the following standards, codes and specifications:
a) ISO 8502-3 Preparation of Steel Substrates before Application

of Paints and Related Products – Part 3 –
Assessment of Dust on Steel Surfaces Prepared
for Painting (Pressure Sensitive Tape Method)
b) ISO 8503-1 Part 1 Specification and definitions for ISO

surface
profile comparator for the assessment of abrasive

blast cleaned surfaces
c) ISO 8503-4 Part 4: Methods for calibration of ISO surface

profile
Comparator and for the determination of surface

profile - Stylus instrument procedure.
d) SIS 055900 Pictorial Surface Preparation Standard for

Painting Steel Surfaces.
e) SSPC-SP1 Steel Structure Painting Council
In case of conflict between the requirements of this specification and that of above referred
Documents, the requirements of this specification shall govern.
The CONTRACTOR shall be familiar with the requirements of these documents and shall
makethem readily available at the site to all personnel concerned with carrying out the
worksspecified in this specification.
MATERIALS AND EQUIPMENT
Field joint anti-corrosion coating material shall be heat shrinkable wraparound

sleeve suitable for a maximum operating temperature of (+) 60°C (max. T) and
shall conform to designation EN 12068-C-HT-60 UV. In addition, the field joint anti-
corrosion coating shall comply the requirements
Heat shrinkable wraparound sleeves:
GWSSB 106
Heat shrinkable wraparound sleeve shall consist of radiation cross-linked, thermally

stabilized,ultraviolet resistant semi-rigid polyolefin backing with a uniform thickness
of high shearstrength thermoplastic/co-polymer hot melt adhesive. The joint coating
system shall consist ofa solvent free epoxy primer applied to the pipe surface prior
to sleeve application. The backingshall be provided with suitable means (thermo-
chrome paint, dimple, or other means) toindicate the desired heat during shrinking
in field is attained. The sleeve shall be supplied inpre-cut sizes to suit the pipe
diameter and the requirements of overlap.
The total thickness of heat shrinkable wraparound sleeve in the “As Applied”
condition shall beas follows:
Pipe Size Thickness (mm)
(Specified Outside Diameter)
On Pipe Body On Weld

Bead
Average Min. Min.
<30” (762.0mm) 2.0 1.8 1.6
>32” (813.0mm) 2.4 2.2 2.0
The heat shrink wraparound sleeve shall have the required adhesive properties
when appliedon various commercial pipe-coating materials. The pre-heat and
application temperaturesrequired for the application of the shrink sleeve shall not
cause loss of functional properties ofthe pipe coating.
The Contractor shall propose only those coating systems that have been previously
used forpipelines of size same or higher than the size indicated in tender, for a
length of 50 km andabove in a single project for similar operating conditions.
Functional Requirements of Field Joint Coating
Properties of the PE backing shall be as follows:
S.No. Properties Unit Requireme

a. TensileStrength@+25oC N/mm2 nt >12
b. UltimateElongation@+25o % >250
C
GWSSB 107
S.No. Properties Unit Requireme

c. Dielectricwithstandwith100 KV nt >30
0
d. Water % <0.05
absorption@+25oC
e. For24hours
VolumeResistivity@+25 oC Ohm- >1015
cm
Functional Properties of Joint Coating System (As supplied)
Asappliedfieldjointcoatingsystemshall
complytherequirementsofDINEN12068,correspondingtodesignationEN12068–
CHT60UV,exceptasmodifiedbelow:
a) CathodicDisbondmentResistanceat Tmaxi.e.60o C
shallbe20mmwhentestedasperAnnexureKofEN12068.Testshallbecarried
outat(+)60oC.
b) Peel Strengthshallbe asfollows:
Peel Strength Unit Requirementfor

Mech.Resistanc
e Class-
InnertoInner(+) @23o N/mm C(minimum)
1.5
OutertoInner C
@Tma N/mm 0.3
OutertoOuter @23o N/mm 1.5
C
@Tma N/mm 0.3
ToPipeSurface @23o N/mm 3.5
C
@Tma N/mm 0.5
ToFactoryCoating @23o N/mm 3.5
C
@Tma N/mm 0.5
ContractorshallobtainpriorapprovalfromEmployerregarding theManufacturer ofthejoint

coatingmaterialandthespecific gradeofthejointcoatingsystem.Completetechnicaldetails
alongwith testcertificatescomplyingwiththerequirementsand shallbe
submittedtoEmployer forthispurpose. TheContractorshallfurnishtestcertificates froman
independent DINrecognized/approvedlaboratory for alltheproperties required
forthespecifiedENdesignationoffieldjointcoatingandtherequirementsofthisspecification
Cut back
Cut back length of the precoated pipes shall be 150mm ±10mm
Field joint coating system shall be of suitable width considering an overlap to the
factory coated pipe coating by minimum 50 mm on each side 3 LPE coated pipes.
APPLICATION PROCEDURE
GWSSB 108
General
The application procedure shall be in accordance with manufacturer’s instructions

and the minimum requirements specified below whichever are the most stringent
and shall be demonstrated to and approved by the Employer. Manufacturer’s
expert shall supervise the application and shall be available at site upon request
during qualification of application procedure and during construction at
Contractor’s cost.
Operators for coating application shall be given necessary instructions and training
before start of work, by the Contractor. To verify and qualify the application
procedures, all coating applied during the qualification test, shall be removed for
destructive testing as detailed subsequently in this specification. Contractor shall
only utilize those operators who have been approved/pre- qualified by the field joint
coating manufacturer.
Oil, grease and salt shall be removed from steel surface by wiping with rags
soaked with suitable solvents such as naphtha or benzene. Kerosene shall not be
used for this purpose. Solvent cleaning procedure according to SSPC-SP1 shall be
followed.
Each field joint shall be blast cleaned using a closed cycle blasting unit or an open
expendable blasting equipment. With the first equipment type, steel or chilled shot
and iron grit shall be used and Garnet material with the second one (in case the
authority having jurisdiction have no objection, the contractor may adopt sand
blasting instead of garnet material). During blast cleaning the pipe surface
temperature shall be simultaneously more than 5oC and more than 3oC above
ambient Dew Point, while the ambient Relative Humidity shall not be greater than
85%. Prior to surface cleaning the surfaces shall be completely dry. The surface
shall be cleaned to a grade Sa 2½ in accordance with Swedish Standard SIS-
055900 with a roughness profile of 50-70 microns. Surface roughness profile shall
be measured using an approved profile comparator in accordance with ISO 8503-1
and shall be calibrated prior to the start of the work in accordance with ISO 8503 or
ISO 8503-4. The blast cleanliness shall be checked on every joint and the
roughness profile shall be checked 1 every 10 joints.
Dust, grit or foreign matter shall be removed from the cleaned surface by an
industrial vacuum cleaner. The dust contamination allowed shall be of a rating max
2 as per ISO 8502-3. The frequency of checking for dust contamination shall be 1
every 10 joints.
Blast cleaned field joint shall be coated with 2-4 hours according to the
conditions below:
• RelativeHumidity(RH)>80% - 2hours
GWSSB 109
• RelativeHumidity(RH)70-80%- 3hours
• RelativeHumidity(RH)<70% - 4hours
Pipesdelayedbeyondthispointorpipesshowinganyvisible
ruststain,shallbeblastcleaned again.
The field joint surface shall be inspected immediately after blast cleaning and any
feature of the steel surface such as weld spatter, scabs, laminations or other
imperfections considered injurious to the coating integrity, made visible during blast
cleaning, shall be reported to the Company Representative and on permission from
Company Representative, such defects shall be removed by filling or grinding.
Pipes affected in this manner shall be then re-blasted cleaned if the defective area
is larger than 50mm in diameter.
The ends of existing pipe protective coating shall be inspected and chamfered.
Unbounded portions of the coating shall be removed and then suitably trimmed.
Portions where parent coating is removed shall be thoroughly cleaned as specified.
The adjacent chamfered areas of the line pipe coating shall be cleaned and
abraded, to expose a clean uniform fresh surface of uncontaminated factory
applied coating.
All steel joint surfaces shall be thoroughly examined before the application of the
coating in order to ensure the surfaces are free of oil, grease, rust, mud, earth or
any other foreign matter. All these substances shall be removed before coating, to
the procedures herein described.
Protection coating shall be applied on the joints immediately after the completion of
cleaning operation.
Application Procedure for Heat Shrink Wraparound/Sleeves
Inadditiontotherequirementsstatedabove,followingshallbecompliedwit
h:
The wraparound sleeve shall be of a size such that a minimum overlap of 50mm is
ensured (after shrinking) on both sides of the yard applied corrosion coating of
pipes.
Inthecaseswherecarrierpipe isinstalled bydirectboring/jacking, theoverlaponthemill

coatingfortheleadingedges ofthejointsshallbeminimum200mm.
Whenthisextraoverlap isachievedbyprovidinganadditionalpatch
ofheatshrinktape/wraparound,itshallbeapplied insucha
mannerthatthesquareedgeofthepatchonthejointcoatingis inthedirection
oppositetothe directionofboring/jacking.
Before centering the wraparound sleeve, the bare steel surface shall be preheated
either with a torch moved back and forth over the surface or by induction heating.
The minimum pre-heat temperature shall be as recommended by manufacturer and
GWSSB 110
shall be checked by means of contact type temperature-recording thermometer

(Digital Pyrometer with flat probe type contact). Temperature indicating crayons
shall not be used. Pre-heat temperature shall be checked on every joint. Care
shall be taken to ensure that the entire circumference of the pipe is heated evenly.
Temperature measuring instruments shall be calibrated immediately before the
start of the works and thereafter at intervals recommended by the manufacturer of
the instrument.
Upon pre-heating, the pipe surface shall be applied with two pack epoxy primer of
wet film thickness 150 microns or as per manufacturer’s recommendation
whichever is higher, to cover the exposed bare metal of the welded field joint and
10mm min. onto the adjacent pipe coating if recommended by the manufacturer.
The wet film thickness of the primer shall be checked on every joint with a wet film
thickness gauge prior to installation of sleeve. Thickness gauge shall be calibrated
once per shift.
Immediately after application of epoxy primer, the wraparound sleeve shall be

entirely wrapped around the pipe when the epoxy is still wet. Sleeve shall be
positioned such that the closure patch is located to one side of the pipe in 10 or 2
O’clock position, with the edge of the undergoing layer facing upward and an
overlap of min. 50mm. Gently heat by appropriate torch the backing and the
adhesive of the closure and press it firmly into place.
A heat shrinking procedure shall be applied to shrink the sleeve in such a manner
to start shrinkage of the sleeve beginning from the centre of the sleeve and heat
circumferentially around the pipe. Continue heating from the centre towards one
end of the sleeve until recovery is completed. In a similar manner, heat and shrink
the remaining side. Shrinking has been completed when the adhesive begins to
ooze at the sleeve edges all around the circumference.
The complete shrinking of the entire sleeves shall be obtained without undue
heating of the existing pipe coating and providing due bonding between pipe,
sleeve and pipe coating. The installed sleeve shall not be disturbed until the
adhesive has solidified.
The joint coating application shall be done under supervision of the manufacturer’s
personnel during the field trial demonstration and testing work. Presence of
manufacturer’s representative is a mandatory requirement and bidders are required
to furnish specific commitment to this. Minimum 50 (fifty) field joint coating to be
carried out under supervision of the joint coating supplier’s representative.
Application procedure and environment protection methodology demonstrated at
the time of field trial shall be strictly followed during the entire work.
REPAIRS
If a field joint is detected to be unacceptable after testing as per relevant QA

section of this specification the Contractor shall, at his own cost:
GWSSB 111
(i) Determinethecauseofthefaultyresultsofthefieldcoating.
(ii) Mobilizetheexpertofmanufacturer,ifrequired.
(iii)
TesttothecompletesatisfactionofCompany,alreadycompletedfieldc
oatings.
(iv)
Stopthefieldcoatingworksuntilremedialmeasuresaretakenagainstt
hecausesof suchfaults, totheentiresatisfactionoftheCompany.
Contractor shall replace all joint coating found or expected to be unacceptable as

per relevant section of this specification.
Contractor shall, at his own cost, repair all areas where the coating has been
removed for testing by the Company.
After the coating work on welded joints and repairs to the coating have been
completed the coating as a whole shall be tested with a spark-tester before
lowering or jacking the pipeline.
Employer shall be entitled to check the coating on buried pipelines or parts of

pipelines with equipment such as the “Pearson Meter” and the resistance
meter. If coating defects are established, the Contractor shall be responsible for
excavation at such points, repairing the coating, spark testing and backfilling the
excavations without extra charge.
DOCUMENTATION
Prior to procurement of coating materials, Contractor shall furnish the following

information for qualification of the Manufacturer and material.
a)Complete information as per DIN EN 12068 along with descriptive technical

catalogues.
b) Test certificates and results of previously conducted tests, for all properties
listed .
a) Reference list of previous supplies, in last 5 years, of the similar material

indicating the project details such as diameter, quantity, operating
temperature, year of supply, project name, contact person and feedback
on performance.
OncetheEmployer’sapprovalhasbeengiven,anychangeinmaterialorManufacturersha
ll benotifiedto
Employer,whoseapprovalinwritingofallchangesshallbeobtainedbeforethe
materialsaremanufactured.
GWSSB 112
Prior to shipment of materials from the Manufacturer’s Works, Contractor shall

furnish the following documents:
a) Testcertificates/resultsasperManufacturer’sQualityControlProcedurefor
eachbatchof material.
b) Specificapplicationinstructionswithpictorialllustrations.
c) Specificstorageandhandlinginstructions.
All documents shall be in English language only.
3.2 SPECIFICATION FOR EXTERNAL COATING FOR SPECIAL

SECTIONS, CONNECTIONS & FITTINGS OF BURIED STEEL PIPELINES FOR
WATER
3.2.1 General:
Special sections, miterbends,tees,connections,fittingsin buried

steelpipelinenetworkshallbecoated externally, with
prefabricatedpolyolefintapecoatingasperAWWAC209-00. The
Contractorshallperformall workinaccordancewith
thesespecificationsandthelatestpipelinecoatingpractices, andshallcompletethe
workinallrespectstothefullsatisfaction oftheOwner /Owner’sRepresentative.The
entirecoatingoperation
startingfromcleaningandsurfacepreparationtillcoatingshallbeperformedunderthesup
ervisionofskilled personnel whoarewellconversantwith thework.Pipes
whichhavebeencleaned andprimed,
orcleaned,primedandcoated,withouthavingbeeninspectedandapprovedshallbereject
ed.
This specification is not intended to be all inclusive and the use of guidelines set
forth here does not relieve the Contractor of his responsibility for the quality and
performance of the applied coating system, and to supply coating material capable
of performing its intended service.
3.2.2 Referenced Standards:
The following standards (latest revision) referenced below are a part of this
specification. In case of conflict between this specification and the referenced
standards, this specification shall apply.
(a) ANSI/AWWAC209-
StandardforColdAppliedTapeCoatingsfortheExteriorofSpecialSections,
GWSSB 113
Connections,andFittings forSteelWaterPipelines.
(b) ANSI/AWWAC214-StandardforTapeCoatingSystemsfortheExterior
ofSteelWaterPipelines
(c) SSPC-SPl-Solvent Cleaning
(d) SSPC-SP6/NACENo.3-CommercialBlast Cleaning
3.2.3 General:
The buried steel pipeline special sections shall be protected with hand or manual
machine applied cold applied tape protective coating conforming to AWWA C209 -
00 (Cold Applied Tape Coating Systems for Exterior of Steel Water Pipelines).
Protective coating shall consist of a coating system consisting of primer, inner -

layer tape and outer-layer tape. Work or material that fails to conform to this
standard may be rejected at any time before final acceptance
3.2.4 Coating system:
The pre-fabricated polyolefin tape coating system shall consist of the following
layers to provide an applied coating system thickness of 100 mils (2.5mm) on the
exterior of the special sections of steel pipes.
1. Aliquidadhesivelayer.
2. An inner-layertapeforcorrosionprotection
havingthicknessof30milsandappliedwith50%overlap
3. Anouter-
layertapeformechanicalandUVprotectionhavingthicknessof20milsandappliedwith50
%overlap.
3.2.4.1 Liquid Adhesive layer:
The liquid adhesive layer shall consist of a mixture of suitable rubber and synthetic
compounds and solvent. The liquid adhesive layer shall be brush applied to the
abrasive blasted prepared pipe surface before application ofthe inner-layer tape.
The function of the liquid adhesive is to provide a bonding medium between the
pipe surface and the inner-layer tape.
The liquid adhesive shall be supplied by the manufacturer that supplies the inner-
layer tape. The liquid adhesive shall not settle in the container forming a cake or
sludge that cannot be easily mixed by hand or mechanical agitation and it shall
have good machine-application properties.
TableI-Physical Propertiesofthe
GWSSB 114
LiquidAdhesive
Color Base Weight FlashPoint

Flammable - 6-8lb/gal(0.72–0.965g/l) -10oF(-
Black Rubberand orgreater
Non - 10 –12lb/gal(1.20–1.44kg/l) none

SyntheticResi
3.2.4.2 Inner-layer tape:
The inner-layer tape shall be a two-layer tape consisting of a polyolefin backing

layer with a laminated butyl- based adhesive layer. The inner tape shall be
compatible with the liquid adhesive. The manufacturer shall certify that the
backing material shall be polyolefin only, containing not more than 3.5 percent, by
weight, of non- polyolefinic material consisting of carbon black and antioxidants.
The inner-layer tape shall be applied after the liquid adhesive and before the
outer-layer tape.
The backing and adhesive shall be made from materials that provide high
electrical resistivity, resistance to corrosive environments, low moisture absorption
and permeability, and shall provide an effective bond to a primed steel surface.
The inner-layer tape shall be of material that will resist excessive mechanical
damage during normal application operations and shall be sufficiently pliable for
the intended use. The inner-layer tape shall withstand, without tearing, the tensile
force necessary to obtain a tightly wrapped inner coating free of voids. The inner-
layer tape shall be supplied in roll form wound on hollow cores with a minimum
inside diameter of 38mm.
The thickness of the inner tape shall be 30mils.
To ensure a proper smooth coating by hand or by manual hand wrapping

machine, the inner-layer tape shall be provided in standard widths of 4” or 6” as
per manufacturer recommendations consistent with the pipe diameter.
3.2.4.3 Outer-layer tape:
The outer-layer tape shall be a two-layer tape consisting of a polyolefin backing

layer with a laminated butyl adhesive layer. The manufacturer shall certify that the
backing material shall be polyolefin only containing not more than 3.5 percent, by
weight, of non-polyolefin material consisting of pigments, antioxidants and
stabilizers. The outer layer shall be compatible with the inner-layer tape The
primary function of the outer tape layer is to provide mechanical protection to
mechanical and outdoor weathering (UV) protection to the tape system, and
secondarily, to contribute to the overall corrosion-protection properties of the
system. The outer- layer tape backing shall be compounded so that it will be
resistant to outdoor weathering.
GWSSB 115
The outer-layer should be of suitable quality for the local environment, as follows:
 Storage Temperature : 0 to 500C.

 Over-ground Condition : 0 to 600C.
Under-ground Condition : 70C to
350C.
 Ultraviolet-ray Protection : Required in outer layer.
Materials used in the outer-layer tape shall have high electrical resistivity, low
moisture absorption and permeability, and shall provide mechanical protection
during handling and outdoor storage. The outer-layer tape shall be sufficiently
pliable for normal application operations by hand or by manual hand wrapping
machine and shall form an effective bond to the inner-layer tape. The outer-layer
tape shall be supplied in roll form wound on hollow cores with a minimum inside
diameter of 38mm
The thickness of the outer-layer tape shall be 20mils.
To ensure a proper smooth coating by hand or by manual hand wrapping

machine, the outer-layer tape shall be provided in standard widths of 4” or 6” as
per manufacturer recommendations consistent with the pipe diameter.
3.2.4.4 Coating-system Thickness:
The installed coating system thickness shall not be less than 100 mils (2.5mm)
and shall comprise of the following.
1. A liquid adhesive layer (50-75 microns)
2. An inner-layer tape (Nominal 30 mils i.e. 0.75mm) applied with 50%

overlap
3. An outer-layer tape (Nominal 20 mils i.e. 0.50mm) applied with 50%

overlap
The properties of the tape & coating system shall conform to the following
requirements.
Table– I - Physical Properties of Total System
Property Requirement
Minimum Maximum
Thickness 95 mil 105 mil
100 mil, nominal
GWSSB 116
Dielectric breakdown 400v/mil
Water-vapor transmission, 0.25 perms ([1.44ng/

max. (Pa.s.m2)]
Insulation resistance 500,000 mega ohms (min)
Adhesion to Primed Steel 20 ozf/inch
3.2.5 Coating Application:

3.2.5.1 General:
The coating application shall be a manual operation starting with properly abrasive
blasted pipe surface.
Longitudinal & spiral welds of the pipe shall not exceed a height of 3/32 inch
(2.4mm) above the pipe surface andshall be ground flush a full 18 inch (450mm)
along the length of the pipe from both ends prior to the coatingprocess.
Steps, which shall be performed consecutively, shall consist of (1) liquid adhesive
application by brush; (2)application of the inner-layer tape directly onto the
prepared pipe surface with 50% overlap; and (3) applicationof the outer-layer tape
directly on top of inner-layer tape with 50% overlap.
3.2.5.2 Pipe preparation:
3.2.5.2.1 Metal surface condition:
Bare pipe shall be free from mud, mill scale, mill lacquer, wax, coal tar, asphalt,
oil, grease, or any other foreignmaterial. Before blast cleaning, surfaces shall be
inspected and pre-cleaned according to SSPC-SP 1 to removeoil, grease, and
loosely adhering deposits. Visible oil and grease spots shall be removed using a
solvent. Onlysolvents that do not leave a residue shall be used. Preheating to
remove oil, grease, and mill scale may be usedprovided that all pipe is preheated
in a uniform manner to avoid distortion.
After drying and removing all loosely adhering foreign materials, the pipe surface
shall be cleaned by blastingwith grit or sand to achieve a surface preparation at
least equal to that specified in SSPC:SP6/NACE3. The blastanchor pattern or
profile depth shall be 1 mil to 3 mils (25 μm to 75 μm) measured in accordance
with ASTM
D-4417.
The cleaned exterior pipe surface shall be in inspected for adequate surface
preparation. Surface imperfections,such as slivers, scabs, burrs, weld spatter, and
GWSSB 117
gouges, shall be removed by hand filing or grinding if necessaryto prevent

holidays.
Blast-cleaned pipe surfaces shall be protected from conditions of high humidity,

rainfall, or surface moisture.
No pipe shall be allowed to flash rust before coating. To ensure a dry pipe surface
at the time of liquid adhesiveapplication, the minimum steel substrate temperature
shall be 21°C and at least 3°C above the dew point.
3.2.5.3 Coating Application:

3.2.5.3.1 Liquid adhesive application:
The liquid adhesive shall be applied in a uniform thin film at the coverage rate
recommended by themanufacturer. The liquid adhesive shall be thoroughly and
continuously mixed and agitated during applicationto prevent settling. The liquid
adhesive shall be applied to the entire exterior surface of the pipe by brush
tocover the entire exterior surface of the pipe.
The liquid adhesive coat shall be uniform and free from floods, runs, sags, drips,
or bare spots. The liquid adhesive-coated pipe surface shall be free of any foreign
substances, such as sand, grease, oil, grit, rust particles, or dirt.
Before applying the inner-layer tape, the liquid adhesive layer shall be allowed to
touch dry in accordance withthe manufacturer's recommendation.
3.2.5.3.2 Application of inner-layer tape:

The inner-layer tape shall be applied directly onto the prepared pipe surface by
manual tape coating machine.
When applied to spirally welded pipe, the direction of the tape spiral shall be
generally parallel to the weldspiral. The minimum overlap shall not be less than
50%. When a new roll of tape is started, the ends shall beoverlapped at least 150
mm measured circumferentially.
3.2.5.3.3 Application of outer-layer tape:

The outer-layer tape shall be applied over the inner-layer tape using the same
type of manual tape coatingmachine used to apply the inner layer tape. The
overlap of the outer-layer tape shall not coincide with theoverlap of the inner-layer
tape. The minimum overlap shall not be less than 50%. When a new roll of tape
isstarted, the ends shall be overlapped at least 150 mm measured
circumferentially.
3.2.5.3.4 Cutbacks
Coating cutback shall be 150 mm±10mm.
3.2.6 Material acceptance

Acceptance of the proposed coating materials shall be approved by the Owner /
Owner’s representative.
GWSSB 118
The tape manufacturer proposed by the Contractor should have supplied at least
30% quantity of tape requiredfor this project and as per this specification in a
single contract for pipe diameter ≥ 900mm in the last five years.
Work completing certificates from End User & coating applicator will be submitted
by the Contractor whilesubmitting credentials of the proposed tape manufacturer
to the employer for approval.
3.2.7 Coating repair in field:

All holidays visually or electrically discovered either at the coating plant or in the
field shall be repaired bypeeling back and removing the outer and inner layers
from the damaged area. The exposed areas shall then becoated with liquid
adhesive and either (1) a length of inner-layer tapes shall be wrapped around the
pipe to cover
the defective area; or (2) a patch of inner-layer tape shall be applied directly to the
defective area as specified bythe Owner’s Representative. The minimum over-lap
at the damaged area shall be 100 mm all around. Therepaired area shall be tested
with a holiday detector as per specifications after the repair is completed.
Ifholidays are not found, the repaired area shall be covered with the outer-layer
tape with a minimum over-lap of100 mm beyond the inner-tape patch.
3.2.8 Hoisting:
Special sections, fittings, miter bends etc. shall be hoisted using only wide-belt
nylon slings or the equivalent.
The use of caliper clamps, metal chains, cables, tongs, or other equipment likely
to cause damage to the coatingshall not be acceptable, nor shall dragging of the
pipe be permitted. The Contractor shall allow inspection of thecoating on the
underside of the pipe while the pipe is suspended from the slings.
3.2.9 Shipping, handling and storage:

Coated pipe sections shall be handled, stored and shipped in a manner that will
prevent damage to the coating.
Pipe sections, fittings also shall be handled and stored in a manner to prevent
damage to pipe walls and ends.
Pipe sections or coating damaged in handling or other operations shall be

repaired. Handling during the periodof coating also shall be such as to avoid
damage to the coating. Thermal expansion is a characteristic of thecoating that
may cause uneven areas on the coated pipe surface, but does not adversely
affect the coatingsystem's performance. These areas do not require any repair.
Stacking: Sufficient spacers or padding shall be .used to prevent damage to the

pipe sections and coating.
Shipping: Pipe sections, fittings etc shall be transported from the coating yard to
the jobsite using sufficientshoring or tonnage, padding and banding to adequately
protect the pipe and its coating.
GWSSB 119
Loading: Pipe sections, fittings shall be loaded for shipping in compliance with
existing shipping standards andregulations.
Trench-side Storage: Pipe sections, fittings stored along the trench side shall be
suitably supported off theground to avoid damage to the coating.
3.3 Lowering and Jointing
3.3.1 The pipe shall be lowered into the trenches by removing only one or two struts at a
time. It shall be seen that no part of the shoring is disturbed or damaged and, if
necessary, additional temporary struts may be fixed during the lowering operations.
It shall also be necessary to see that the outside coating of pipe is not damaged in
anyway during the lowering and assembling .After the pipe is lowered into the
trench, it shall be laid in correct line and level by using the leveling instruments,
sight rails, theodolite, etc. Care shall be taken to see that the longitudinal joints of
two consecutive pipes at each circumferential joints are staggered by 90. While
assembling the pipes, the ends shall have to be brought close enough to leave a
uniform gap not exceeding 4mm. If necessary, a marginal cut may be taken to
ensure a close fit of the pipe faces. For this purpose, only experienced cutters who
can make uniform and straight cuts, shall be permitted to cut the faces of the pipes.
No extra payment shall be made for such marginal cutting. There shall be no lateral
displacement between the pipe faces to be joined. If necessary, spiders from inside
and tightening rings from outside shall be used to bring the two ends in perfect
contact and alignment. It may also be necessary to use jacks for this purpose. In no
case shall hammering or longitudinal slitting be permitted. When the pipe is properly
assembled and checked for correct line and level, it shall be firmly supported on
wooden beams and wedges and tack welded. Some portion of the trench may be
refilled at this stage so as to prevent the pipeline from losing its alignment. The tack
welded circumferential joints shall then be welded fully. Only experienced welders,
who shall be tested from time to time shall be permitted to carry out the welding
work.
On completion of the pipe jointing and external protection, the trench shall be cleaned
of outside coating rebound. The welding shall be filled and compacted in 150mm
layers with the bedding material. Backfilling shall be carried out as detailed here
under.
3.3.2 Precautions against Floatation

When the pipeline laid underground or above ground in a long narrow cutting gets
submerged in water collected in the trench of cutting it is subjected to an uplift
pressure due to buoyancy and is likely to float if completely or partly empty. In the
design of pipelines, provision is to be made to safeguard against floatation providing
sufficient overburden or by providing sufficient dead weight by means of blocks, etc.
Factor of safety for calculations for check against floating shall be taken as 1.2.
In the case of works extending over one or more monsoon seasons, however, special
care and precautions are necessary during the progress of work on this account. The
Contractor shall close down pipe laying operations well in time for the monsoon. The
work of providing blocks, refilling the earth to the required level, compacting the same,
etc. shall always be done as soon as the pipeline in the cutting has been laid.
The Contractor shall see that the water shall not be allowed to accumulate in open
trenches. Where work is in an incomplete stage, precautionary work, such as blank-
GWSSB 120
flanging in the open ends of the pipeline and filling the pipeline with water etc. shall be
taken up as directed by the Engineer.
Such works shall be to the Contractor's account and no separate payment shall be
made for the same. The Contractor's rate for pipe laying shall be deemed to include
such precautionary measures against floatation.
Protection of the pipeline against floatation during the Contract Period shall be the
responsibility of the Contractor. Should any section of the pipeline float due to his
negligence, etc. the entire cost of laying it again to the correct line and level shall be to
his account.
3.4 CLEANING, DISINFECTIONING AND COMMISSIONING OF THE PIPELINE
3.4.1 Upon completion of a newly laid main, the main shall be disinfected as directed by
the Engineer.
3.4.2 The main shall be flushed prior to disinfection except when the tablet method is used.
After initial flushing, the hypochlorite solution shall be applied to the water main with
mechanically or electrically powered chemical feed pump designed for feeding
chlorine solutions. For small applications, the solution may be fed with a hand pump.
3.4.3 In the case of main of large diameter, water from the existing distribution system or
other approved source of supply shall be made to flow at a constant measured rate
into the newly laid pipe line. The water shall receive a dose of chlorine also fed at a
constant measured rate. The two rates shall be proportioned so that the
concentration in the water entering the pipeline is maintained at no less than 300
mg/l. The chlorine shall be applied continuously and for a sufficient period to develop
a solid column of 'Slug' of chlorinated water that will as it passes along the line
expose all interior surfaces to a concentration of at least 300 mg/l. for at least 3
hours. As the chlorinated water flows past tees and crosses related valves and
hydrants shall be operated so as to disinfect the appurtenances.
3.4.4 In the case of newly laid mains in which scrupulous cleanliness has been exercised
the tablet method can be adopted and in this method, the initial flushing is dispensed
with. The calcium hypochlorite tablets are placed in each section of pipe and also in
hydrants, hydrant branches and other appurtenances. The tablets shall be attached
by an adhesive and must be at the top of the main. The main shall then be filled with
water and the water shall remain in the pipe for at least 24 hours.
3.4.5 After the applicable retention period, the heavily chlorinated water shall be flushed
from the main until the chlorine concentration in the water leaving the mains is not
higher than that generally prevailing in the system or less than 1 mg/l.
3.4.6 After final flushing and before the water main is placed in service, a sample or
samples of water shall be collected from the end of the line and tested for
GWSSB 121
bacteriological quality and shall show the absence of coliform organisms. If the initial
disinfection fails to produce satisfactory samples, disinfection shall be repeated until
satisfactory, samples are obtained before the main is placed in service.
3.4.7 The Contractor is expected to carry out the disinfection work as a part of laying the
pipes and his rates for laying the pipes should include the disinfection and other
connected works till the main is placed in service, unless otherwise specified in the
schedule.
3.5 DISTANCE INDICATORS AND MARKINGS
3.5.1 The Contractor shall supply and fix indicators on either side of major crossings along
the buried pipe line. Indicators shall consist of 10 cm x 10 cm precast concrete posts
1.25 meter long, set 0.75 meter into the ground and painted white above ground
level. The description shall be written in blue at one face of the precast post.
3.5.2 In case of the pipeline laid above ground details such as chain age, Invert levels of
pipe, appurtenance number, pedestal / saddle number, culvert number, anchor /
thrust block number etc., shall be suitably marked either on the pipeline or the
supporting structure etc., in distinct color. The Bidder / Contractor shall include the
cost of this in his rates for the other items.
3.6 Sand Bedding:
3.6.1 The sand bedding of minimum 300 mm thickness and level shall be provided below
pipe, prior to laying the pipe in trenches. It shall be compacted with a light hand
rammer. Any reduction in thickness due to compaction shall be made up by adding
sand during ramming. For the purpose of the bedding under this item only screened
fine sand of grain size not larger than 2mm shall be used. The sand shall be clean,
uncoated and free form clay lumps, injurious amounts of dust, soft particles, organic
matter, loam or other deleterious substances.
3.6.2 If the sand supplied is unclean it shall be washed. In no case shall sand containing
more than 3.5 % by dry volume or 5% by wet volume of clay, loam or silt be
accepted. Tests specified for determining silt in sand and organic impurities as
described in IS:383 shall apply. Sieved and washed sand shall be stored on the
works in such a manner as to prevent intrusion of any foreign matter, including
coarser particles of sand or any clay or metal or chips. Tests as indicated above shall
be performed if called for by the Engineer at the expense of the Contractor.
3.6.3 During the work of providing sand bedding and laying the pipeline over it, loose
material from the sides or edges of the trench shall be prevented from falling inside
the trench, by providing shoring and taking other measures. Also where necessary,
trench shall be kept dry by pumping out seepage water continuously.
3.7 Refilling of trenches:
GWSSB 122
3.7.1 On completion of the pipe laying operations in any section, for a length of about
100m and while further work is still in progress, refilling of trenches shall be started
by the Contractor with a view of restricting the length of open trenches. Pipe laying
shall closely follow the progress of Trench Excavation and the Contractor shall not
permit unreasonably excessive lengths of trench excavation to remain open while
awaiting testing of the pipeline. If the Engineer considers that the Contractor is not
complying with any of the foregoing requirements, he may prohibit further trench
excavation until he is satisfied with the progress of laying and testing of pipes and
refilling of trenches. The excavated material nearest to the trench shall be used
filling. Care shall be taken during backfilling, not to injure or disturb the pipes, joints
or coating. Filling shall be carried out simultaneously on both sides of the pipes so
that unequal pressure does not occur. Walking or working on the completed pipeline
unless the trench has been filled to height of at least 30cm over the top of the pipe
except as may be necessary for tamping etc., during backfilling work.
The remaining portion of the trench may be filled in with a mixture of hard and soft
material free from boulders and clods of earth larger than 150mm in size if sufficient
quantity of good earth and murrum are not available. The trench shall be refilled so as
to build up to the original ground level, keeping due allowance for subsequent
settlement likely to take place. The top 300mm layer or fertile agricultural soil shall be
kept aside during excavation and shall be laid in layers near ground level during
refilling.
3.7.2 To prevent buckling of pipe shell of diameters 1200mm and above, pipes shall be
strutted from inside while the work of refilling is in progress, for which no separate
payment shall be made.
Strutting shall be done by means of strong spiders having at least 6 arms which shall
be sufficiently stiff to resist all deformation. Spiders shall be provided at a maximum
interval of 2m& shall be welded in such a way that internal coating does not get burnt.
3.7.3 The Engineer shall, at all times, have powers to decide which portion of the
excavated materials shall be for filling and in which portion of the site and in what
manner it shall be so used.
If any material remains as surplus it shall be disposed of as directed by the Engineer,

which includes loading, unloading, transporting and spreading as directed within all
lead. If the Contractor fails to remove the earth from site within 7 days after the period
specified in a written notice, the Engineer may arrange to carry out such work at the
Contractor's risk and cost or may impose such fine for such omission as he may deem
fit. Particular care shall be taken to keep the trench dry during the entire refilling
operation.
If suitable material for refilling is not available for excavation the Contractor shall bring
earth, murrum of approved quality as directed by the Engineer.
No mechanical plant other than approved compacting equipment shall run over or
operate within the trench until backfilling has reached its final level or the approval of
the Engineer has been obtained.
GWSSB 123
3.7.4 Subsidence in filling in : Should any subsidence take place either in the filling of the
trenches or near about it during the maintenance period of 12 months from the
completion of the Contract Works, the Contractor shall make good the same at his
own cost or the Engineer may without notice to the Contractor, make good the same
in any way and with any material that he may think proper, at the expense of the
Contractor. The Engineer may also, if he anticipates occurrence of any subsidence,
employ persons to give him timely notice of the necessity of making good the same,
and the expenses on this account shall be charged to the Contractor.
3.8 BOX PUSHING THROUGH EMBANKMENT
Providing and casting reinforced concrete approved design mix design mix Box of the
size as per GAD, including providing and casting steel cutting edge for front shield,
MS rear shield R.C.C. M-20 for thrust bed, thrust wall for pushing the box below
railway embankment under railway / roads under running traffic condition as per
contractors own design / drawing including arrangements for intermediate jacking
station with provision of intermediate shield and its connections with the box drag
sheets as may be required for smooth controlled pushing etc. complete in all
respects, including cost of necessary excavation with its all lead & lift for constructing
thrust bed at designed level as directed by Engineer-in-Charge including providing all
temporary works as required & approved by Railways authority, required protection
of existing road pavement / railway tracks including providing water tight joints in
R.C.C. box segments using CC grout with epoxy paint on exposed facing and
providing R.C.C. saddles in the box as per details given with drawing for supporting
pipe in the box as directed, including all plans and machinery, equipments, all labour,
materials & all temporary works in all respects, dismentaling and removal of
temporary work, restoring ground to its original profile on completion of work.
The work also includes sealing of box at both ends after completion etc. as directed
by engineer-in-charge.
3.8.1 SPECIFICATIONS FOR CASTING RCC BOX & PUSHING THROUGH

EMBANKMENT
In order to avoid interference to railway traffic / excavation on existing roads

intercepted on pipeline alignment, BOX PUSHING technique is envisaged in
preference to any other conventional methods for the laying of pipeline through such
railway & road crossings intercepted.
The R.C.C. box segments shall be cast using concrete grade of approved design
mix in suitable segments as per the approved design, and pushed across the
embankment by hydraulic jacks, of suitable capacities excavating manually the soil
under the FRONT SHIELD of the box.
The thrust bed required for box pushing shall be of required width and of length and
thickness as per design approved and laid along the longitudinal axis of proposed
box. The thrust bed is envisaged in reinforced concrete using grade M-20 and
designed to resist the reaction induced due to jacking force while pushing the box
inside the embankment. The reaction due to jacking force shall mainly be resisted
by frictional resistance between thrust bed and the earth. However, additional keys
GWSSB 124
provided at the bottom of the bed shall be made use of to develop more resistance
due to passive pressure of the earth.
The concrete below the bottom of each pin pocket shall be done first for positioning
them. Aligning these pin pockets is very important aspect while casting the thrust
bed in order to avoid any lateral shifting of the box with respect to it's axis.
Therefore, these boxes shall be held in position by welding MS bars between boxes
in longitudinal and lateral directions. While concreting for entire thrust bed is carried
out, two recesses shall be left along the entire length of the thrust bed at top for
housing rails. Leveling of these rails shall be done by providing suitable MS packing
Coils at suitable spacing. These recesses shall then be filled with screed mortar.
Also, 50 mm thick screed shall be laid on top of the thrust bed and leveled such that
the top of rails shall remain 2 mm protruding above top level of the thrust bed. The
pin pockets shall be covered with precast cover slab before screeding. The thrust
bed shall be laid in a slope of 1:700 to avoid lifting of box during pushing.
In order to facilitate jacking and steering, it is envisaged to cast the box in segments
of suitable lengths. The first box shall be provided with FRONT SHIELD and REAR
SHIELD. The front shield shall consists of M.S. Plate with suitable stiffeners.
Anchor bars, welded to the Plates shall be embedded in the concrete of the box.
The front shield shall be 1.0 M wide on all four faces with 0.50 M width embedded in
box concrete. Similarly, rear shield shall be provided at the rear end of each box.
Half the width of rear shield shall be embedded in box concrete with outer face
being flush with outer surface of the box. For the front 0.50 M length of box, the
thickness of top and bottom slab and both sides shall be reduced by 30 MM. so that
rear end of the first box and at front end of remaining box pockets, suitably lined
with 6 mm thick M.S. Coils shall be provided to house hydraulic jacks for
intermediate jacking. Two pockets shall be provided in the side walls of box, just
below top Haunches and two shall be provided in bottom slab of box, next to
Hauches.
The box is designed as a normal box but subject to longitudinal thrust while pushing.
8 mm thick M.S. Plates shall be laid over rails placed in thrust bed to form bottom of
box along the length. The bottom surface of these Coils shall remain flush with the
bottom of the box. These Plates shall be anchored in bottom slab concrete with
welded anchor bars. With this arrangement, while pushing the box over the thrust
bed, the contact between steel to steel surfaces shall reduce friction. Before casting
the box, polythene sheets suitably greased shall be laid on the top of thrust bed &
bottom of box to prevent contact between thrust bed and bottom of box and facilitate
pushing with very smooth, frictionless surface between the thrust bed and bottom of
the box.
To withstand reactions of jacking force, jacking pins are provided with M.S. bar
handle to facilitate the lifting when required. The overall dimensions of the pins shall
ensure smooth insertion and lifting inside pin pockets.
A jacking rig, fabricated from M.S. Plates and structural steel shall be provided to
ensure proper alignment of jacking force. One end of the jacking rig shall have
GWSSB 125
saddles to house hydraulic jack. The clear width inside rig shall be more than pin
pocket to ensure smooth sliding of rig. Spacers fabricated from M.S. Plates shall be
used for filling gaps between hydraulic jack and jacking pin while pushing. These
spacers shall be meant to rest against jacking pin at one end and jack ram at the
other end.
After completion of casting of box, pushing operation shall commence with the rigs
laid on top of the thrust bed with one end of the rig resting against face of the rear
end of bottom slab of the first box. The hydraulic jacks shall be properly housed in
the rig so that one end of jack shall rest against the end plate of the rig. The other,
ram side of the jack shall rest against face of jacking pin. When the jack shall be
operated, the ram shall be pushed against the jacking pin. This will make the box to
move in the direction of thrust away from jacking pin. When the full displacement of
ram be obtained, the jacks shall be closed and spacers shall be inserted between
the jacking pin and the jacks. the jacks shall be operated again and the box shall be
pushed in the direction of thrust. When the rig travel to expose next row of pin
pockets, the jacking pin shall be removed and installed in the next row of pin
pockets. This process shall be repeated till the front shield shall cut into the
embankment for about 1.0 M.
The excavation at the front end of the box shall be carried out manually within front
shield. the muck shall be removed from the box. When about 0.50 M of excavation
shall be done, the jacks shall be operated again so that front shield shall be pushed
for 30 or 40 cms further inside the embankment. Again, the excavation shall be
continued till the entire length of first box is fully pushed inside the embankment.
When rear end of the first box shall be very close to the embankment, the second
box shall then be cast and after adequate curing, pushed to lock inside the rear
shield of the first box. Hydraulic jack shall be housed in intermediate jacking pockets
and an intermediate jacking station shall be opened up. The operation of the jacks
in the intermediate jacking station shall be similar to that in the initial stage.
However, in this case, the ram shall rest against plate lining in pockets. After
opening the intermediate jacking station, the intermediate jacks shall be operated
while the rear end of 2nd box shall be made to anchor against the jacking pin
through the jacks.
In General following sequence shall be adopted in carrying out the job :

a) After casting thrust bed, polythene sheets suitably greased shall laid on the top
of thrust bed as above explained to prevent contact between thrust bed and
bottom of box.
b) The reinforcement cage required for base slab with reinforcement for side walls
shall be placed in position on bed. The precast blocks or chairs for provision of
cover shall be provided under the cage.
c) The base slab and side walls up to top of bottom haunch would be concreted
with M-25 grade concrete in one operation leaving the top of side wall rough.
d) The reinforcement cage for side wall shall be laid in proper position. The lap
length shall be provided properly. The side walls shuttering shall be provided by
proper checking of alignment & vertically up to bottom of top haunch.
e) The surface of hardened concrete shall be thoroughly hacked, swept clean,
wetted and covered with a layer of neat grout. The neat grout shall be applied to
the top and this shall be followed by a 10 mm thick layer of mixed the same
proportion as that of and sand in concrete and concreting shall be resumed
immediately thereafter. The first batch of concrete shall be rammed against the
GWSSB 126
old work to avoid formation of any stone pockets particular attention being paid
to corners and closed spots and the concreting of side walls shall be carried out
up to the bottom of top haunch.
f) The reinforcement cage for top slab shall be laid properly on centering and
chairs or precast units for providing cover shall be laid under cage. The
centering shall be checked in alignment and props shall be of sufficient strength.
g) Concreting of top slab shall be carried out in the same manner as per 5 above.
h) Pushing of the completed segments of the box shall be commenced as per the
procedure described in above paras till the entire length of the box in the
embankment is built up.
i) After completion of jacking, pressure grouting of concrete shall be carried out of
fill joint between segments to make then water tight and the inside face of the
joint treated with smooth finishing and box indicators shall be placed at both
ends of box showing necessary details of box and communication. Both ends
shall be closed with BB Masonry keeping provision of air vents.
3.9 CROSSING
3.9.1 GENERAL SPECIFICATIONS

At public highways, or at such other crossings as are shown in the construction
drawings issued by the company the pipeline shall be installed in MS casing
pipe conforming to the specifications given herein.
(a) The casing pipes shall be installed in accordance with the details given in
drawing and the casing, bushing and insulators, etc., shall be installed on
the carrier pipe as detailed in drawings. Casing pipe size shall be as per
approved drawing of sanctioning authority, Casing shall be installed with
even bearing throughout its length and shall slope towards one end, as
specified or desired by the engineer-in-charge. The ends of the casing shall
be sealed to outside of carrier pipe in accordance with the details given in
drawing.
(b) Before installation, holes for installing vent pipes shall be cut and burrs if any
shall be removed. The welding of both carrier pipe and casing pipe shall be
done in accordance with the welding specifications, given herein. Before
installing the casing pipe, it should be cleaned of all internal obstructions and
during installation care should be taken to keep the inside clean.
(c) The section of carrier pipe to be placed in any casing shall be closed at each
end, hydrostatically tested preferably with dead weight tester for at least two
hours. Only on successful completion of this test, shall the carried pipe
section be inserted in the casing pipe. The installation of casing may open
cut as circumstances may permit or require as directed by the engineer-in-
charge.
(d) The installation of casing in bended section of the carrier pipe shall be
performed by meter bends of the casing pipe provided that the length of
each meter cut out of casing pipe shall be such as to provide a clearance of
at least 1-1/2" between the inside of the casing pipe and the outside of the
coated carrier pipe.
(e) Excavation for casing installation shall be immediately backfilled at the
completion of the work with suitable solid matter and packed thoroughly to
prevent seepage of water into the excavation.
GWSSB 127
3.9.2 ROAD AND IRRIGATION CANAL CROSSINGS :
(h) At road and canal crossings the work shall be performed to the
specifications of local authorities or such public bodies as may be in charge
(S) of roads and canals to be crossed.
(i) In case, however the minimum requirements of the governing agencies are
less than those set out in the drawing or the specifications given herein,
then the requirements given in the drawings and the specifications given for
encased line shall be followed.
(j)
(k) Where as the casing pipe in the case of encased line to be laid normal by
boring, tunneling, engineer-in-charge may at his discretion permit open-cuts
to be made for the installation of casing provided, however, that the
TENDERER shall procure the necessary permit / license for the same from
competent authority. At locations wherein the open cut methods are
permitted, the TENDERER shall pass the carrier pipe through the casing
located in the trench after the approval of the engineer-in-charge in writing ,
if Open Cut method is not permitted by authority, pipe is to be laid through
Push Through Method. and care shall be exercised to avoid damage to pipe
coating and wrapping during this operation. The TENDERER shall produce
a certificate in writing from concerned authorities for its satisfactory
restoration and payment therefore.
(l) At all crossings the carrier pipe shall be laid straight without bends so that if
necessary the pipe at a later date may be replaced without cutting the
casing. The carried pipe shall extend at least 2 meters beyond the end of
casing pipe at either end.
(m) At road crossings the TENDERER shall eliminate unnecessary bending of

pipe to conform to the contour of ground by gradually deepening the ditch at
such approaches as directed by the engineer-in-charge. Where the
installation of the casing has been made by open cut TENDERER shall
install suitable temporary bridge work ensuring the safety of the traffic aids
and safeguards for protection of the public safety, or he shall provide
suitable diversions as desired by the engineer-in-charge.
(n) At all railways pipeline crossings shall be bored with horizontal boring
machine.
(o) The method of carrying out a cased crossing by boring for various crossings
on this pipeline route shall be jointly inspected by the representative of the
COMPANY and TENDERER for each category of work prior to
commencement of actual work.
GWSSB 128
(p) Pipeline under Road Track and irrigation canal an applicable portion of the
right-of-way shall be encased in accordance with the specification. This item
of work shall include, necessary clearing and grading required therefore,
trenching to the depths and widths required, welding of casing and carrier
pipes, testing, lowering in, installation of vent assembles, end seals,
insulator and all other fittings that may be required, backfilling, clean up,
complete restoration to the original condition and further strengthening and
protective works as may be required. The work shall be carried out in
accordance with the drawings and as directed by the engineer-in-charge.
For various operations mentioned above, the specifications pertaining to
these operations shall apply in addition to the specifications given herein.
The TENDERER shall be permitted to use William Sons type Neoprene seals in
place of concrete end seals for the crossings. The item shall be procured by the
TENDERER himself as per the provisions under the appropriate head of work in
case TENDERER so desires. The representative of the COMPANY may also be
associated to determine the quality of the material and its delivery schedule from
the open market. However, the particular work defined under the proper head
shall not be delayed on account of non-availability of Neoprene end seals. In
such case, concrete seals may be provided.
On both ends of pushing concrete supports are to be provided as per direction of

engineer-in-charge.
GWSSB 129
VALVES:
GENERAL
ValvesshallbeasperrelevantISorinternationallyrecognizedstandards.Flangesshall
bemachinedonfacesandedgesto ISO7005,IS6392orBS4504.Flangedrillingshould
confirmto IS 1538, Table-IV & VI.
Valvesshallbedoubleflangedtypeandthefacesshallbeparalleltoeachotherand flange
face should be at right angles to the valvecenterline.Backsideofvalveflanges shall be
machined or spot faced for proper seating of the bolt head and nut.
Valveburiedorinstalledinundergroundchamber,whereaccesstoahandwheelwould be
impractical, shall be operated by means of extension spindle and/or keys.
Valveshallbesuitableforfrequentoperationaswellasoperation afterlongperiodsof
idleness in either open or closed position.
The valve stem, thrust washers, screws, nuts and all other components exposed to
the sewage shall be of a corrosion resistant grade of stainless steel.
Valves shall be free from sharp rejections.
Valves shall have pressure rating min. PN 1.6 in general.
TheContractorshallprovideOperatingplatform foreasyopen/closeoperationofvalves
wherever the valves hand wheel is higher than 1.25 mabove floor level.
SLUICE VALVE:
A. GENERAL:
CastIronSluice Valves shall be manufactured strictlyinaccordancewithand

conforming to Indian standard specification IS : 14846 – 2000 or its latest
amendment.
Thevalvesareintendedtobeusedinvertical/horizontal position.Valveshallberising/ non-

rising spindle type as specified having pressure rating PN1.6 in general or higher as
requiredasperapplicationasspecifiedinthesespecificationsandfreefrom sharp
projectionswhicharelikelyto catchandholdstringymaterials.Boltsandnutsshall conform
toIS1363:1967andIS4218:1967.Overalldimensionlike,facetoface distance, height of
valveetc shall conformto IS 14846.
B. FEATURES OF CONSTRUCTION:
BODY &BONNET
Body&Bonnetshallbedesignedso astowithstandtheratedtestpressureasspecifiedin IS:

14846. Bodies of the valve shall be fitted with seat rings securely fixed in machined
recesses by proper engineering practice.
Reasonable clearances shall be provided behind the rear faces of the flanges on
body and bonnet to provide free access to use spanners for assembling &
GWSSB 130
dismantling. Rear sideof valveflangesshallbemachinedorspotfaced

forproperseatingofbolthead,washerand nut.
ValvesshallhaveGunmetal/SS304drainplugofrequiredsizeasperIStofacilitate drain of
trapped water fromthe valve body.
FLANGES
Valveflangefacesshallbeparalleltoeachotherandshallbeatright angle to the valve

centerline.Theflanges andtheirdimensions ofdrillingshallbeinaccordancewiththe
requirementsofIS1538,TableIV&VI.Therearsideoftheflangesshallbemachined or shall
have spot face to provide proper tightening of Nut & Bolts.
STUFFING BOX
Theglandandstuffingboxwhichcomeincontactwithspindleshall be provided with

bushing ofminimum3mm thickness and of material as specified in IS-14846 or
specifiedin specificrequirementofthisspecificationasanti-frictionaldevice.The minimum
inside dimensions of the stuffing box shall be in accordance with IS 14846.
Valve shall be provided with back seat bush to facilitate repacking of valves in
pressurized condition without disturbing the pump operation.
WEDGES
TheValvesshallbewithequaltaperedsolid DIwedgemadeinonepiece.Valvesshall
haveperfectmachinedandpressedWedgeseatrings securely fixed intomachined
recesses.Thewedgeseatringshallridehighonthebodyseatringtoallowforwear,
whenshut.Theminimumweartravelshallbe 25 %ofthefacewidthoftheseatringsas
specifiedinIS.
SEATRINGS
Thedimensionsofthebodyseatringsandwedgeseatringsshallconform toIS 14846. The

wedge seat rings & body seat rings shall be securely riveted over and above
sufficient hydraulic press fittings.
GUIDES & LUGS
Allvalvesshallbeprovided withtheguidesandlugstoguidethewedgethroughitsfull travel

in body. The channel and shoe arrangement shall be secured by non – protruding
rigid rivets of nonferrousmetals. The clearance between lugs and guides for different
sizes of sluice valves shallbe as specified in IS 14846.
STEM & WEDGE NUT
ValveStemshallhaveamachinecut,singlestart trapezoidal threads of such length that

thewedgecanberaisedtoapositionsoastoensurefullflowpassagethroughthevalve’s
bore. In fully closedpositionofthevalvethestem shall remain in full contact with

wedge nut foritsentirelengthwithatleast10mm projection.Thelengthofthestem
particularlybelowthecollarshallbekeptaccordingly.Thedimensions of stem and
GWSSB 131
wedge nut shall be in accordance with IS: 14846.
Thestem ofvalveshallbesoscrewedasto closethevalveswhenthecap,handwheelor

crankhandleisrotatedinclockwisedirection.Thedirectionofclosingshallbemarked on the
Cap / hand wheel.
Whereverextendedspindleisprovided,thevalveshallalsobeprovidedwithsuitable
headstock.
Rising Spindle Sluice Valve shall be with the Yoke andYoke Sleeve (Spindle Nut)
placed in the Yoke, in such a way that the axial movement of the Yoke Sleeve is
avoided in the yoke along direction of spindle axis andbut it cannot rotate. Integrally
formed end of the Spindle shall be locked in Wedge and Rotation of the yoke sleeve
shall Open / Close the wedge responding to direction ofrotation. The design shall
offer minimum operating torque to operate the valve.
The ball type thrust bearing may be provided above and below the collar of the
yoke sleeve to minimize the operating torque
aspermanufacturerdesign.Thespindlethreads shall be engaged in the operator drive
sleeve for the rising spindle sluice valve offered with gear box and / or electric
actuator.
GEARS
Gearsshallbeofsuitabledesign(IS2535:1978)andworkmanship,soastoensure
satisfactory working of sluice valve.
ACCESSORIES:
1. Valvesabove300mmsizeshallbeprovidedwithRepackingarrangementasper
IS 14846.
2. TheValves600mm&abovesizeshallhavechannelandshoearrangementas per
IS 14846.
3. The Valves above 500 mm size shall have by pass arrangement as per IS 14846.
4. TheValves350mmsize&aboveshallhavespur/bevelgeararrangementasper
IS 14846.
5. AllValvesshallhavevalve’sOPEN/CLOSEindicatorarrangementasperIS
14846.
6. Valvesabove300mmsizeshallbeprovidedwithPositionIndicatorindicating
extent of opening / closing of gate/wedge.
C. MATERIAL OF CONSTRUCTION:
GWSSB 132
The specific requirement shall be considered as under:
 Body : CI
 Bonnet : CI
 Non rising Stem : High tensile brass, IS 320 / 6912, Gr.HTB-2 /
FHTB-2
or Stainless Steel, IS 6603, Gr.12Cr1304Cr
18Ni10
04Cr17Ni.12 MO2
 Wedge : DI
 Stem Nut : Leaded tin Bronze, IS: 318,Gr.LTB-2
 Body seat ring, wedge face : Leaded tin Bronze, IS: 318, Gr.LTB-2 ring &
bushes.
 Gland packing : Jute & Hemp, IS: 5414
 Hand Wheel : CI
 Nuts : Carbon steel, IS–1363(Part-3), Class 4.0
 Bolts : Carbon steel, IS-1363 (Part-3), Class 4.6
 Bonnet Gasket : Rubber, IS-638, Type -B
D. MARKING:
The following information shall be embossed on each valve body:
• ISI Certification Mark.
• The manufacturer's name or Trade Mark.
• Pressure Rating of valve.
• The size of valve in mm.
• Heat number of cast.
GWSSB 133
BUTTERFLY VALVE
Resilient seated butterfly valve shall be as per IS 13095-1991/ BS 5155. Valve shall be
suitable for mounting in any position.
The valve seat shall be of integrally cast or replaceable design. When the valve is fully
closed, the seat shall sit firmly so as to prevent leakage. The seat surfaces shall be
machined smooth to provide a long life for the seal.
All fasteners shall be set flush so as to offer the least resistance possible to the flow
through the valve.
Valve shall be suitable for throttling purpose.
All valve, spindles and hand wheels shall be positioned to give good access for
operational personnel.
Valve of diameter 450 mm and above shall be provided with enclosed gear
arrangement for ease of operation. The operation gear shall be such that they can be
opened and closed by one man against an unbalanced head 15% in excess of the
maximum specified rating. Valve and any gearing shall be such as to permit manual
operation in a reasonable time and not exceed a required rim pull of 400 N.
All hand wheels shall be arranged to turn in a clockwise direction to close the valve, the
direction of rotation for opening and closing being indicated on the hand wheels.
Specification & M.O.C. of Butterfly valve:
General
 Type : Both end flanged hand wheel / Gear

operated
 Rating of valves : PN1.0/PN 1.6
 Menu. Standard : IS-13095:1991 / BS 5155
 Sizes and quantity : As per Price schedule
Material of construction
 Internal Hardware : S.S. AISI-304

 Body./ Disc : CI
 Body ring( Retainer/seat) : Stainless steel ; AISI -304
 Shaft Stainless steel : AISI-410
 Disc seat : EPDM rubber/ Nitrile rubber
 Bush & Thrust Pad : G.M. IS :318 LTB-2 / Teflon
 Body seat : S.S. AISI-304
GWSSB 134
EXPANSION BELLOWS
The metallic single expansion bellows with all parts shall be manufactured as per
EJMA standards. The rating of metallic expansion bellows is PN 1.0 / PN 1.6.The
bellow shall have both flanged ends of suitable thickness. Material of construction for
bellow elements and all other parts are tabulated below. Bellow shall have minimum
axial extension of 5 mm & minimum axial compression shall be 15 mm. It adequate
capacity to compress and expand within the limit mentioned in its entire life cycle of
minimum 7000 cycles. It shall be retained for the entire design period. The period shall
have to be mentioned by the bidders. Bellows shall have to be subjected to hydrostatic
test at 15 Kg/ cm² / 24 Kg/ cm² for hold time of 30 minutes.
Materials of Construction for expansion bellows
 Bellows / Collar / Internal sleeve : SS 240 GR 304

 Limit Rods : CS IS: 1363, CL-4.6
 Nut & lock nut : CS IS: 1367, CL-4.0
 Lugs / Flanges / Welded : IS: 2062 Gr. B
GWSSB 135
TEMPER PROOF AIR VALVE
Providing and supplying C. I. Air valves of approved make & quality of following class
and diameter including GST and all taxes if any, insurance, transportation, freight
charges, inspection charges, loading, unloading, conveyance to departmental stores,
stacking etc. Lowering, laying and jointing in position following Air valves including
cost of all labour, jointing material, including pipe, nuts & bolts etc. all fixtures and
giving satisfactory hydraulic testing etc. The cost should also include fixing valves
with DI pipes complete:
General
The contractor shall be covering manufacturing, supplying and delivery of:
Air valve conforming to IS: 14846 or its latest revision (Specification for Air valves with ISI
certification).
Classification
 Air valve shall be of two types
(a) Single Air valve
(b) Double Air valve
 Single air valve shall have single small or large orifice for releasing air during pipe
filling and ventilating the pipe during emptying. Air valves up to 40 mm dia shall be
directly screwed on the main.
 Double air valve having two ball chambers on outlet of large capacity shall be
provided for admission and release of bulk volume of air during emptying and filling
of the main. Another of small outlet type for the escape of smaller quantities of air
accumulating under pressure. They shall be of flanged type.
Materials
 Cast Iron
Cast Iron for bodies’ pressure covers, splash covers, glands, caps, joints support
rings shall be best gray iron of selected grade, 20 of I-S-210-1978 specification for
grey iron castings.
 Gun Metal
Gun metal shall be of mixture of 88% copper, 10% tin and 2% zinc having excellent
hard wearing qualities, Ball guides of small orifice units and outlet bushes of large
orifice valves shall be of gun metal.
 Forged Bronze
Nipples, spindles shall be machined from rolled, extruded or forged high tensile brass
or aluminum bronze. The produce shall possess much greater strength than ordinary
cast product.
 Mild Steel
Bolts, nuts, flanges etc. shall be of mild steel unless otherwise specified and shall
confirm to IS: 226-1975 specification for structural steel.
 Material for Balls
GWSSB 136
The balls shall be of rubber covered and vulcanite covered. The rubber shall have a
smooth and hard surface. It shall be as per IS: 638-1965 specification for rubber and
insertion jointing.
 Flange Jointing Materials
The jointing material used between the flanges of components part of the valve shall
be compressed fiberboard or rubber of thickness between 1.5 mm to 3 mm. The
rubber shall be as per I.S. 683:1965 specifications for rubber and Insertion jointing.
The fiberboard shall be impregnated with chemically natural mineral oil and shall
have a smooth and hard surface.
Dimension
Dimension of the Air Valves shall be as per relative item mentioned in Schedule B of
the tender.
Characteristics
 Small orifice valves shall have rubber covered balls and nipples of forged
bronze or special alloy in to brass plug.
 Large orifice valve shall have vulcanite-covered ball closing on rubber sealing
backed with leather and gunmetal outlet bushes. They shall be screwed or
flanged. The flanged shall be faces and drilled to ISS.
 Air valves shall be sound in all respect and uniformly forged so as to have
uniform bore. They shall be free from any defects such as unwanted
projection, holes or roughness and shall have inner and outer surface
perfectly smooth.
Coating
 Immediately after casting and before machining, all cast iron parts shall be
thoroughly cleaned and before rusting commences shall be coated by dipping
in a bath containing a composition having a tar base.
 The coating shall be such that it shall not impose any test of small to water.
The coating shall be smoothing glossy and sufficiently hard. It shall not
chipped when scratched lightly with the point of penknife.
Inspection and Testing
 The Engineer-in-charge or his authorized representative shall have free
access to the works for inspection at any stage of manufacture and to reject
any materials, which does not confirm to the specified requirements.
 The manufacturer shall arrange to supply all labour and appliance for the
tests if the testing is to be done at his works. Each valve shall be subjected to
the hydraulic test and shall show no sign of leakage under these tests, i.e. the
balls shall function properly. The valve shall be tested to double the maximum
working pressure.
Manufacturer’s Guarantee
The manufacturers shall guarantee that if any defects chargeable to faulty
workmanship, design or materials are found in the valves within a period of one year
of dispatch be shall replace any part that prove defective, free of charge at the place
of dispatch.
Information Required
The following information shall be cast on each valve body:
(a) Manufacturer’s name or trademark.
(b) Size of valve
Tender Price
GWSSB 137
The tender price shall include all labour, material and machinery cost necessitated to
be utilized for:
a) Proper manufacturing of the valves
b) All tests required to be undertaken at manufacturer’s premises
c) Transportation of the valves either by rail and/or road services with all the covers duly
and appropriately insured
d) Delivery of specials with proper loading, unloading, stacking at BHAVNAGAR store
as indicated by Engineer-in-charge
(e) Further towards proper discharge of all contractual obligations, the storage of all
specials to be manufactured, supplied and delivered under the scope of contracts shall in
general be made as described in Technical Specifications document
Marking
The methods of marking all the valves to be delivered under scope of contract shall
ensure that all the information will remain legible even after transportation, storage in
open space etc. In general the legible and indelible marking upon the valves shall
indicate the followings:
a) Manufacture’s brand name and/or trademark
b) Diameter and class of valves
c) Any other important matter that the manufacturer or purchase deems fit to be
inscribed
Packing and Handling
 The materials shall always be packed separately dispatched from
manufacturer’s works with adequate protective measures to prevent damages
deterioration while in transport or stored at any place. The packing shall
always be so neat and tidy that may withstand any robust and rough handling.
 When the materials are transported at railway risk, special packing as per
IRCA rules are absolutely necessary for which the extra cost, if any, shall be
borne in total by supplier only.
 The supplier shall use proper handling instruments/equipment’s and shall
follow to a suitable method of handling pipes as may be approved by
Engineer, while unloading and stacking material in the stores.
Materials and Workmanship

 General requirements of materials and workmanship shall mean any material
or article either raw or finished one is required to be used in the
manufacturing process of tanks.
 All the material shall be new and of high quality.
 In case, if material is not specified by relevant ISS for manufacturing part or
the whole as item, the supplier shall prepare specifications in concurrence
with manufacturer and shall seek an approval of Engineer prior to its use in
the manufacture.
Test Certificate
 The supplier shall always provide manufacturer’s test certificate in
accordance with every batch/lot of goods so manufactured and supplied.
 The supplier shall also produce in addition to manufacturer’s test certificate as
mentioned under “inspection & testing above”, the inspection certificate
issued by the employer or his authorized person / agency appointed.
Inspection
GWSSB 138
This clause is applicable in general to all materials such as all types of valves, pre-
cast chambers, other specials and materials etc. which are to be supplied by the
contractor.
Inspection of materials will be carried out at factory site by engineer-in-charge /
agency appointed by client.
The inspection call for Air Valves should be given. Inspection will be carried out
normally within one weeks time and on receipt of such intimation the inspecting
agency will inspect the materials as per the specification and on satisfying itself, will
mark the inspection marks on all pipes and issued inspection note to the supplier and
concerned consignee.
For inspection purpose the manufacture has to go in for stenciling for identifying size
and class for proper segregation. The stock of offered material shall be in a
manageable batch with adequate space like spreading the pieces etc. to permit
proper inspection and inspection authority to be present during stamping so as to
ensure that only actually cleared material is stenciled. Manufacturer does not load
material after sunset to avoid inadvertent dispatch of wrong material.
Inspection note issued by the inspection agency to supplier as well as consignee

(Concerned Executive Engineer) materials with inspection mark will be dispatched to
stores stipulated in supply order and on receipt at stores the verification will be
carried out by concerned Deputy Executive Engineer as regards quantity and quality.
Here quality means physical soundness of materials as precaution against breakage
during transit. The supplier has to submit the test certificate as well as detailed test
results carried out by inspection authority to the consignee along with the dispatch
documents of materials. The material shall be considered as received only on receipt
given by the concerned Deputy Executive Engineer after verifying and satisfying the
above requirements.
Lowering, Laying & Jointing the Air Valve

Air Valves, Single Ball, Flanged / Screwed Type
i. The single acting air valve shall be supplied and carted by the contractor as per
latest IS. The rate shall include loading, unloading and stacking at site.
ii. The materials shall be carted to store or site of work including all freight, loading,
unloading including all taxes, insurance, including necessary jointing materials
such as GI Nipple saddle pieces shall be brought by the contractor for fixing of air
valve.
iii. A suitable hole shall be drilled on the pipeline. The pipeline shall be of any type
such as AC, PVC or CI pipes. A clamp shall be got prepared with a nipple welded
on it. The clamp shall be fixed on pipe with bolts and nuts in such a way that the
part of nipple fixed in the clamp shall remain in the hole drilled in pipe. The rubber
packing shall be provided between the clamps and the pipe. White zinc spun yarn
shall be used for fixing the nipple of air valve.
GWSSB 139
iv. Bolt holes shall be drilled according to center-lines. Bolt heads and nuts shall be
hexagonal and shall conform to IS: 1363 (specification for black hexagonal bolts,
nuts and lock nuts and black hexagonal screws).
v. The neoprene seat ring shall be held security in place under the low pressure
cover by jointing support ring to prevent it from sagging when the ball is not
soaking the orifice.
Jointing Material
i. Jointing material shall be brought by contractor with all necessary joint rings,
nuts, bolts and washers for completing the joints on all the flanges of valve
supplied under this contract including these flanges which will be jointed to pipe
system. The lengths of bolts shall be assumed to be suitable for jointing material
supported under the contract shall be inclusive of rates.
ii. Joint rings shall be of flat section at least 3 mm thick. They shall be of rubber in
accordance with Is: 638-1965 or its latest edition (specifications for rubber and
insertion jointing) of hardness proven in practice so as form a water tight joint and
use of jointing paste shall not be allowed.
Air Valves, Double Ball, Flanged Type
General
i. The double acting air valves shall have to two ball chambers having one outlet of
large capacity for admission and release of bulk volume of air during emptying
and filling of the main and another having small outlet for escape of smallest
quantities of entrapped air, This type of air valves shall be of flanged type with full
conformation with IS: 1538 same valve shall be supplied and carted by the
contractor as per latest IS. The rate shall include loading, unloading and stacking
at site.
ii. The ball sealed orifice always remains open while air is exhausting and is
immediately closed when water rises in the chamber, lifts the ball and seals the
orifice. It shall also ensure that there are no recesses or pockets, sheltering,
escaping air for the large orifice (low pressure) ball to drop into when the valve is
open. Turbulent air at the time of filling of pipe shall not circulate in such cavities
and cause the ball to blown in to.
iii. Double acting air valve shall be bolted-up evenly on all sides after providing
necessary rubber packing etc. on the flange of the Tees. Where facing of the
flange is not true a line, fiber or lead wood or rubber packing shall be used. It
shall be rubber insertion cloth of two plays and of approved quality. Any defects
in jointing observed during the test shall be made good by the contractor till there
is no further leakages are there.
Air Riser
Providing, supplying & installation of air riser pipe (MS) (Flanged pipe) of 6 m length
on the pipeline at suitable place as per design and directed by Engineer-in-charge
including MS flange pipe RCC foundation block & column in CC M-150 etc. complete.
GWSSB 140
Specifications for Air Riser for pipeline are as under:
Column / Footings for Air Riser shall be carried out in cement concrete M-150 using
trap metal as per instructions of the engineer in charge. Materials and workmanship
shall be given in concrete section.
Concrete protection block / column shall be cast in M-150. Minimum cover of

concrete block to Riser Pipe shall be 100 mm all around as directed by Engineer-in-
charge.
The item Air Riser includes the cost of providing and laying cement concrete M-150
base, MS Flanges, clamp, MS flange, nut, bolts, rubber packing and cement concrete
column in M-150 etc. complete.
GWSSB 141
WATER HAMMER CONTROL DEVICES

Designing & Providing, supplying, fixing and delivery of Water Hammer Control
Devices for use on pumping main loop and distribution network of following class
and diameter including GST, all taxes, insurance, transportation, freight charges,
octroi, inspection charges, loading, unloading, conveyance to departmental stores,
stacking etc. complete.
The size and functional requirement shall be as per surge analysis report by the Contractor
during detail engineering. The Contractor shall analyze and design the surge protection
system considering both Bladder Surge Vessel/Surge Anticipation Valve/Zero Velocity
Valveand Air Cushion Valves including regular air valves (for air management in the
pumping main) for safe and satisfactory operation of the system.Negative surge pressure
is not allowed in the water pumping pipelines considering contamination issues and for the
safety of the pipeline against down surge.
Agency has to submit the layout drawing of proposed Surge protection devices along with
theSurge Analysis Report and individual drawing of all equipments for approval well intime
or as directed by the Engineer-in-charge.
 BLADDER SURGE VESSEL
General Scope:
The contractor will have to design, manufacture, and supply Including installation and
commissioning with satisfactory test and trial the surge protection bladdervessel. The
vessel shall be installed at /or near the pump house to protectthe pumping mains from the
adverse effects of the water Hammerwhen the pumps trip off due to the power failures or
sudden stoppage of the pump.The surge tank shall be vertical, bladder type vessel suitable
for use with clearwater.
The Bladder Vessel shall consist of a vertical steel tank with butyl rubber / EDPMbladder,
Isolation Valve, Drain valve, pipes and all necessary appurtenances toarrest surges in
water pumping main.Materials for the tank, design, and shop fabrication and inspection
shall comply with Pressure Equipment standards (IS/ASME/BS5500/CODAP)
The Bladder Vessel specified herein be supplied by a single manufacturer & thecontractor
shall have to maintain the Bladder vessel as per tender conditions from the dateof supply.
The supply and services included in scope of works:
-Design, manufacture, supply, install and commissioning of the bladder surge vessel as per
the Surge analysis report, which has to be carried out by the bidder & the size of vessel
has to be clearly specified
-Design and construction of suitable concrete base for the surge vessel
-Installation of the surge vessel
-Supply and installation of necessary pipes and fittings, valves, portable aircompressor of
adequate capacity, etc., necessary for smooth function of the Bladder vessel.Surge
analysis report shall be submitted.
GWSSB 142
Design and Drawing
The vessel is required to be provided as protection equipment against surgepressures

exerted on the pumping main loop including distribution network. The capacity of the
vesselshall be adequate to restrict the transient surge pressures due to sudden pump
shutdown when the system is operating at ultimate demand and the extreme surge
pressures shallbe restricted to
Maximum: Not more than 1.5 times design pressure

Minimum: Atmospheric
Volume :As per surge analysis report
The bladder surge vessel design shall ensure thatunder no conditions sub-atmospheric
conditions are created anywhere along thepipe line including the pump with installation of
Air Valves at Crest points in the PipeLine network. Similarly the maximum transient
pressure at any point along the pipeline shallnot exceed 1.5 times of design pressure.
The contractor shall carry out his own analysis for designing the bladder surge vessel
based onabove considerations and the data furnished elsewhere.
Material and Workmanship:
The vessel shall be designed, fabricated and tested as per IS: 2825, code forunfired
pressure vessels. The material of construction of the air vessel shall beboiler quality plates
confirming to Grade – I of IS – 2002 or equivalent.
The vessel shall be of welded construction. The welds shall be cleanly finished, freeof
cracks, blow holes, lamination and other defects. The welds shall be radiographically
inspected for the defects like blow holes, cracks, slag inclusion, etc. and if any defects are
found, the particular welded portion will be repaired before dispatch. Radiographic
inspection shall be to the extent of 10% of welding.
The air vessel shall be coated with epoxy paint as specified elsewhere on both the inside
and outside surfaces for longer life.
The vessel shall have Bladder of heavy duty Reinforced Butyl rubber and shall bedesigned
and manufactured by vessel manufacturer. The valid certificate of Bladdermanufacturer
shall be submitted.
Bladder Vessel Fittings:
Air vessel shall be complete with the following fittings and connecting branches(vessel as
well as fittings) which shall be flanged will be conforming to IS – 1537
1) Lifting Arm for the top Flange for movement of the Flange.
2) One 15 mm (min size) ball plug type valve for connecting the air supply to the vessel.
GWSSB 143
3) One 200 mm dia pressure gauge (min size) having scale reading from 0 to 1 ½ the
pressure to which air vessel is designed.
4) An adequate size flanged branch from the vessel for intermediate pipe connection
between air vessel and delivery main branch.
5) 1 No. 100 mm dia. (min size) Drain connection with hand operated valve.
6) Lifting lugs and sturdy supports for mounting.
7) A Ladder for reaching the top of the Vessel
In addition to the above any other fittings/ accessories required for thesatisfactory
operation of the system shall be provided by the contractor as directed by engineer-in-
charge.
All the fittings shall be supplied by the contractor and transported to the site ofinstallation.
These shall be fixed at the proper locations as per the instructions of theEngineer –in-
charge. The fittings shall be fixed to the flanges by bolts, nuts andwashers with necessary
rubber insertion, etc.
The rubber insertion and steel washers as well as necessary fastening bolts andnuts shall
be supplied by the contractor himself and shall be of approved quality anddimensions. The
fittings shall be fixed true to line with the pipe and in plumb, valvesand specials shall be
properly supported until permanent anchors are completed.
All specials and other fittings shall be supplied by the contractor only. The specialsshall be
of steel capable of withstanding the same test pressure to which Air vesselis subjected.
Foundations:
The Air vessel shall be placed on concrete foundation. The contractor shall furnishthe
drawings of the foundations and other layout details of thevessel, piping, fittings, etc.
Tank Installation:
The surge tank shall be installed in accordance with the manufacturer’s/Suppliers suggested
procedures. All supports, piping, valves, and related appurtenances shall be provided and
installed by the Contractor at no additional cost to the Owner.
Painting and Coating:

All painting and coating shall be completed at the factory. Field painting and coating will not
be accepted. The tank interior shall be painted with anti-corrosion epoxy paint with a
uniform layer thickness of no less than 100 microns,. The tank exterior shall be painted with
3 coat zinc based epoxy to a minimum thickness of 110 microns.
Testing & Inspection:
The Air Vessel shall be subject to factory test in presence of Executive Engineer/Engineer-
in-charge or his representative and third party inspection agency approved by client if any.
The scope of inspection is as under:
GWSSB 144
1] Review of raw material test certificate and quality control procedure

2] Dimensional check as per approved design and drawing
3] Review of radiographic test certificate of welding joint of vessel and air receiveras per
standard and dye penetration test certificate of dish ends.
4] The surge vessel shall be hydrostatically tested at 1.5 times the maximum surgepressure
for 15 minutes. During the test, the vessel should not show any unduedeflection, signs of
weakness at any point or leaks through welded joints/ gaskets orother defects.
5] Product inspection, test and certification
Radiographic Tests :
The contractor shall produce all films of radiographic tests. The radiographic tests shall be
carried out in presence of engineer-in-charge. The contractor shall bear all expenses for the
tests.
1.6.2 Hydraulic Testing:
The vessel shall be tested hydrostatically with a testing machine. The vessel shall stand the
test pressure required i.e. 1.5 times the design pressure without showing any signs of
weakness, leak or sweating. The test should be carried out in the presence of the Engineer-
in-Charge to his entire satisfaction The required pressure should be maintained for at least
15 minutes for inspection purpose. The vessel shall be fitted with an accurate calibrated
pressure gauge. Any section showing leak of welded seam will be rejected , and shall be
repaired by cheaping the weld and rewelding, after obtaining permission of Engineer –in-
charge in writing, all such shall be indicated in the logbook for reference. The rejected air
vessel will be retested hydraulically for specified pressures. Accepted vessel shall be
marked with legible mark for identification.
1.6.3 Performance Testing:
After completion of installation of air vessels, the installation will be subjected to performance
test as guaranteed by the contractor in presence of Engineer-incharge.
If the performance is accepted below accepted parameters, the contractor shall repair or
rectify or replace the defective parts as directed by the Engineer till such time the
satisfactory performance is given.
Note: - Fixing of above bladder surge in the site and commissioning of the bladder vessel
including Three year guarantee defect liability period and seven years comprehensive free
maintenance thereafter.
GWSSB 145
 ZERO VELOCITY VALVE
Construction
Body: The Spring loaded self-actuating zero velocity valve has an outer fabricated casing
(Main body) in which a central rod is held by struts. In order to create an annular flow the
included angle of the cone at upstream of the disc should be 50-60 degree and the cone at
downstream of the cone should be 20-30 degree. The barrel at inlet and outlet of the valve
should suit the pipe diameter. The barrels should have minimum length of 250 mm to 500
mm based on the size of valve for the ease of installation.
The total length of the valve should be as per the below table:
Diameter (mm) Total length of the valve (mm)
500 1850
550 1850
600 1920
650 1950
700 2000
750 2100
800 2300
850 2300
900 2350
950 2400
1000 2400
Dim Tolerance +/-15 mm max.

The valve should be provided with 2 to 4 nos. of hand holes of adequate size to facilitate
insertion and removal of springs by hand (if required) without removing the valve from line.
A suitable cover shall be provided on each of the hand hole.
A ‘Bypass pipe’ with a valve of 80 NB for 500-650mm, 100 mm for 700-950 mm and
150NB for 1000 mm and above should be provided for connecting upstream and
downstream sides of Zero velocity valve should be provided. Minimum two plugs should be
provided to mount pressure gauges at the upstream and downstream of the valve.
Adequate transportation support should be provided on the valve as an integral part of the
valve.
Internal: Closing Disc is mounted on 'Central Rod' cladded with Stainless Steel (SS as per
AISI304) for the adequate length so that the disc moves on the cladded portion. Bush of
the disc should be lined securely with Brass sleeve (minimum 3 mm thick) for smooth
sliding of the disc.
GWSSB 146
Disc is held in closed position by a adequate number of 'Stainless Steel Springs' (SS as
per AISI304). The anti-rotation guides should be provided on the edge of 'Central Disc' with
minimum resistance to flow and minimum possibility to lock during sliding of the disc. The
'Anti Rotation Guide' should be cladded with Stainless Steel Strip (SS as per AISI304) and
'Guide Fork' lined with brass liners. The valve should be provided with a 'Stationary Central
Dome' to create an annular streamlined passage for smooth flow of water. Material of
Construction of principal parts:
S. No. ITEMS MATERIAL

a Entry Barrel Shell and Cone
b Exit Barrel Shell and Cone
MS IS:2062 -250 BR Fe. 410W
c Lap Ring
A
d Guide Dome
e Central Shaft (S.S. Lined)
f Spring S.S. 304
g Bypass Pipe Carbon Steel IS 1239 (part-I) /
ASTM 106 B
h Bush for Disc (With Brass inner Bush)

MS IS:2062 -250 BR Fe. 410W
i Bush for supporting ribs
A
j Hand Hole
k Pressure Rating PN 16
l Ends Flange Ends
Painting: 2 (Two) coats of Coal tar Epoxy Paint from inside and outside.
Inspection and Testing:
The Zero Velocity Valves shall be subjected to Hydrostatic body test by applying the rated
pressure for the hydrostatic test. Both the ends (upstream and downstream) of the valve
shall be closed using the dish/dummy ends. In case of more than one valves of same size
and pressure rating, the valves can be joined together from barrel (or bolted in case of
flange ended valves). The Bypass pipe along with valve will be mounted the zero velocity
valve. The bypass valve shall be kept in open condition during the testing. A pressure
gauge shall be mounted on the Zero Velocity Valve to check the applied hydrostatic test
pressure.
The ‘Test pressure’ 1.5 times Design Pressure shall be applied using the hand pump or
motor pump for a duration of 15 (fifteen) Minutes. No water leakage is permissible through
the main body of the zero velocity and bypass valve during the above period.
Method of Measurement
The measurement shall be recorded based on per number of water hammer devices
installed at site.
Payment
As per payment schedule in price bid. Addition or reduction in quantity on pro rata basis
GWSSB 147
TOILET BLOCK
Scope of work includes constructing toilet block (Ladies plus Gents) at each headwork (i.e.
Cheradi and Sarita)
 Excavation in all types of hard & soft soil etc. Providing and casting in situ mass cement
concrete 1:3:6 using granite quartzite trap metal of size 12 mm to 25 mm incl. consolidation
curing etc. complete.
 Filling with available excavated earth (excluding rock) in foundation, and plinth in layers not
exceeding 20 cm in depth consolidating each deposited layer by ramming and watering etc.
complete, as directed.
 Brick work using common burnt clay building bricks having crushing strength not less than 35
kg./cm2 in ramp, steps,& foundation & plinth in Cement mortar 1:5 (1 cement : 5 course sand)
including raking out joints, curing, etc. complete.
 Providing and laying cement concrete M20 for superstructure (above plinth level) with vibrating
curing etc.comp.including formwork,(excluding cost of reinforcement) for structure as
directed.RCC slab and platform.
 Brick masonry in cement mortar (1:6) using common burnt clay building bricks having crushing
strength not less than 35kg/cm2 in foundation & plinth including scaffolding, curing, etc.
complete for walls, parapets, etc. at all levels.
 Providing and applying Interior plain two faced 15 mm thick cement plaster 1:3 with floating coat
of neat cement slurry on R.C.C ceiling where specified on drawing at all levels including
scaffolding ,curing etc complete including Providing and applying 20 mm thick sand faced
cement plaster consisting of 12 mm thick backing coat of CM 1:3 (1 cement : 3 sand) and 8 mm
thick finishing coat of CM 1:1 (1 cement : 1 sand) etc complete including necessary curing,
scaffolding required if any etc. complete.
 Supplying, Cutting, bending, binding and placing in position TMT Fe 415 grade steel as per plan
and design and as per IS 2503 incl. cost of steel and binding with 16 SWG soft iron wire for all
R.C.C work incl. lift up to two floor level confirming to IS 1786.
 Providing and fixing water closet squatting pan (Indian type/Western type W.C pan) size 580
mm (earth work,bedconcrete,footress and trap to be measured and paid for seperately)
(A) Vitreous china long pattern white colour including necessary fittings, water tank, bends etc
complete
 Providing and fixing to wall ,ceiling and floor galvanised M.S pipe (medium duty ) of the following
nominal diameter with pipe fitting and clamps including making good the wall,ceiling and floor
pipes to be tested for a pressure as specified.
 (a) 15 mm dia
 (b) 20 mm dia
 (c) 25 mm dia
 Providing and fixing C.P brass screws down stop tap, Bip tap 15 mm dia polished bright , of
approved make and design ,with all necessary fittings.
 Providing and fixing 150 mmx 100 mm intercepting sewer trap embedded in concrete complete
including excavation and backfilling.
 Consctruction Manhole of size 1.0X.75 mt including necessary excavation ,refilling and removal
of surplush earth within 30 mtlead,inside&out side 15 mm thick cement plaster in cm 1:3. Brick
masonary in cm 1:5 including making inside channel in CC 1:2:4 PVC step including providing
and fixing fibre reinforced medium duty seat and cover etc. complete as per directed.
 Consctruction of inspecting chamberof size .60 m X.45 m including necessary excavation
,refilling and removal of surplush earth within 30 mtlead,B.B.C.C 1:5:10 for
foundation,inside&out side 15 mm thick cement plaster in cm 1:3. Brick masonary in cm 1:5
including making inside channel in CC 1:2:4 PVC step including providing and fixing fibre
reinforced medium duty seat and cover etc. complete as per directed.
 Providing and supplying in standered length ISI mark rigid unplasticised PVC pipes suitable for
potable water with ringfit joint including cost of rings, as per IS specification no. 4985/1988
including all local and central taxes, transportation, freight
charges,octroi,inspectioncharges,loading,unloading conveyance to the departmental stores and
including cost of jointing material etc. complete Test pressure of 4 Kg./cm2 of 160 mm dia for
vent
GWSSB 148
 Providing and fixing C.I Nahali trap ( 100 mm inlet and 50 mm out let conforming to IS :3989
fixed in cement concrete with C.I Soil variety plug bends of required arm including cutting holes
in walls and making good the same in CM (1:4) etc .complete.
 Providing and fixing 150 mm X 100 mm stoneware gully trap with C.I.grating brick masonary in
C.M (1:4) chamber & water tight C.I. cover with frame of 150 mm X 100 mm size P or R type
 Providing and laying (To level or slope) & jointing with stiff mixure of C.M 1:1 salt glased stone
ware pipes of 150 mm dia. Including testing of pipes and joints complete.
 Supplying Rotationally moulded HDPE storage tank with ISI Mark of approved make incl. all
taxes transportation octroi etc. complete. 500 lit. capacity
Storage Tanks With ISI Mark (with outside Black colour & inside lining)
 Providing and fixing PVC door (Sintex or equivalent) with necessary fittings with PVC frame
 Providing and laying white glazed tiles 6mm thick in skirting, risers of steps and dado on 10 mm
thick cement plaster 1:3 and lointed with white cement slurry
 Providing and laying white glazed tiles 6mm thick in flooring laid on a bad of 12 mm thick
cement mortar 1:3 and jointed with white cement slurry.
 Providing and fixing fibre reinforced seat and cover extra heavy duty clear opening with 560 mm
dia in line and level in c.c 1:2:4 and finishing smooth etc. complete as directed.
 Providing and laying jointing with stiff mixure of C.M 1:1 salt glased stone ware pipes 150 mm
dia. Including testing of pipes and joints complete.
GWSSB 149
LANDSCAPE WORKS AND EARTHWORKS: SOFTSCAPE
Site cleaning, soil restoration and earthworks

Trenching in ordinary soil up to a depth of 60 cm including removal and stacking of
serviceable materials and then disposing of surplus soil, by spreading and neatly
leveling and making up the trenched area to proper levels by filling with earth or earth
mixed with sludge or / and manure before and after flooding trench with water
(excluding
cost of imported earth, sludge or manure).
Rough dressing
Rough dressing the trenched ground including breaking clods.
Fine dressing
Fine dressing of the ground
Mixing and spreading of good soil and mannure
Softscape works and plantation
Good garden soil
Supplying and stacking of good earth at site including royalty and carriage upto 5 km
complete (earth measured in stacks will be reduced by 20% for payment
Cow dung manure
Supplying and stacking of well decayed cattle manure at site
Preparation of beds for hedging and shrubbery by excavating 60 cm deep and
trenching the excavated base to a further depth of 30 cm, refilling the excavated earth
after breaking clods and mixing with sludge or manure in the ratio of 8:1 (8 parts of
stacked volume of earth after reduction by 20% : one part of stacked volume of sludge
or manure after reduction by 8%), flooding with water, filling with earth if necessary,
watering and finally fine dressing, leveling etc. including stacking and disposal of
materials declared unserviceable and surplus earth by spreading and leveling as
directed, within a lead of 50 m, lift up to 1.5 m complete (cost of sludge, manure or
extra earth to be paid for separately)
Plantation of Trees, Shrubs, and Hedge at site i/c watering and removal of
unserveiceable material’s as per direction of officer in charge (excluding cost of plant
& water)
Shrubs Plant
Tree plantation
Digging holes(90 cm dia, and 90 cm deep ) in ordinary soil and refilling the same with
the excavated earth mixed with manure or sludge in the ratio of 2:1 by volume (2 parts
of stacked volume of earth after reduction by 20% : 1 part of stacked volume of
manure after reduction by 8%) flooding with water, dressing including removal of
rubbish and surplus earth, if any, with all leads and lifts (cost of manure, sludge or
extra good earth if needed to be paid for separately)
Plantation of Trees, Shrubs, and Hedge at site i/c watering and removal of
unserveiceable material’s as per direction of officer in charge (excluding cost of plant
& water)
Tree plant
Plant Material
Supply of Shrubs - well developed, well branched - 3-4 branches each having 4-5
leaves, preferably in bloom, in polybag of 30x20cm size, disease free. Shrubs shall
have no less than three main stems and shall be well balanced and bushy, with
strongly developed fibrous root systems, Supply shall include labour & equipment
cost of loading, unloading, transport to site, storage & stacking within site in area
protected from dust.
Plant name
Shrub
GWSSB 150
Providing and stacking of Caesalpiniapulcherrima species of height 45-60

cm. in earthen pot of size 20 cm as per direction of the officer-in-charge.
Providing and stacking of Calliandra, emarginata of height 45-60 cm. in
earthen pot of size 20 cm as per direction of the officer-in-charge.
Providing and stacking of Cestrum nocturnum (Raatki Rani) of height 60-
75 cm. with 4-5 branches in bag of size 25 cm as per direction of the
officer-in-charge.
Providing and stacking of Chandni dwarf of height 15-20 cm., well branched in earthen
pots of size 20 cm as per direction of the officer-in-charge. s per direction of the
officer-in-charge.
Providing and stacking of Hamelia patens of height 60-75 cm. with 6-8
branches in poly bags of size 25 cm as per direction of the
officer-in-charge.
Providing and stacking of Hamelia patens (Dwarf ) of height 30-45 cm. with 3-4
branches in earthen pots of size 20 cm as per direction of the
officer-in-charge.
Providing and stacking of Hibiscus rosasinensis of height 45-60 cm. with
3-4 branches in earthen pots of size 20 cm as per direction of the
officer-in-charge.
Providing and stacking of Murraya exotica of height 45-60 cm. in poly bags of size 15
cm as per direction of the officer-in-charge.
Providing and stacking of Nerium oleander (kaner) dwarf of height 30-40 cm. in
earthen pot of size 20 cm as per direction of the officer-in-charge.
Providing and stacking of Tecomagaudichaudi of height 45-60 cm. in earthen pots of
size 20 cm as per direction of the officer-in-charge.
Supply of Trees - well developed, well branched crown - 4-6 branches each having
4-5 leaves, well developed, in 12" pot or polybag, disease free. Trees shall be large
size nursery grown trees pruned during growth to produce a tight well rounded head
and a straight stem clear of leaves or twigs. Trees shall be at least two years old, as
certified by the nursery. Trees shall be 70-100 mm circumference stem when
measured 1.0m from ground level and shall have a clear straight stem of minimum
1.2m. The head shall be well balanced and rounded and contain at least four main
branches with a well-developed secondary branch system and a defined central
leader that has not been pruned, giving an overall height of 1.5m at the time of
planting. Pruning at the time of removal from the nursery will not be permitted. In dry
weather conditions, trees are to be sprayed with approved Anti-transpirant.
Rootballdimensions : diameter 750mm x 750mm deep minimum. Supply shall include
labour & equipment cost of loading, unloading, transport to site, storage & stacking
within site in area protected from dust
Trees
Providing and stacking of Bottle palm of ht. 210-240 cm bottom girth 30-35 cm well
developed in big HDPE bags
Providing and stacking of Lagerstroemia thorelli of height 150-165 cm.in big poly bag
of size 25 cm as per direction of the officer-in-charge.
Providing and stacking of eltophorum species of height 150-165 cm. in big poly bags
Providing and stacking of Peltophorum species of height 150-165 cm. inbig poly bags
Providing and stacking of Plumeria alba of height 165-180 cm. with 3-4
branches and thick stem in big size HDPE bags as per direction of the
officer-in-charge.
Providing and stacking of Plumeria rubra of height 120-150 cm. with 3-4
branches and thick stem in big size HDPE bags as per direction of the
officer-in-charge.
GWSSB 151
Providing and stacking of Spathodeacampanulata of height 150-165 cm.

in big poly bags of size 25 cm as per direction of the officer-in-charge.
Providing & laying Selection no. 1 grass turf with earth 50mm to 60mm thickness of
existing ground prepared with proper level and ramming with required tools wooden
and than rolling the surface with light roller make the surface smoothen and light
watering the same maintenance for 30 days or more till the grass establish properly,as
per direction of officer in charge
GWSSB 152

04 Vol-III-B-Technical Specification For Civil Works

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

04 Vol-III-B-Technical Specification For Civil Works

Uploaded by

Copyright:

Available Formats

TECHNICAL SPECIFICATION CIVIL WORKS

Volume-IIIB: 24x7 water supply project of Gandhinagar

List of Indian Standards for Design of GSR / SUMP:-

Gunniting exterior surface for Civil Structures only

Gunniting the surface in CM 1:2 having thickness of 40 mm to 50 mm (Ave.) for beam,

Gunniting Internal Surface

For top , bottom of ESR/ GSR/tank /cistern

Providing pressure grouting at 5.6 Kg/Sq.cm in required row/zigzag fashion as specified at

Drilling holes for grouting

List of Indian Standards for Design of GSR / SUMP:-

(2) I.S. 456 – 2000 or latest revised.

a) Inlet arrangement Common inlet chamber with separate inlet gate

c) Scour The sumps shall be provided with scour

d) Overflow The sumps shall be provided with overflow

e) Free Board The sumps shall be designed with a minimum

1.2 Criteria for preparation of designs:

2. Shape & type.

4. Site plan showing location.

6. Plan showing piping arrangement.

7. Design parameters proposed to be adopted for detailed design.

1.3 Design Requirements:

2 PUMP HOUSE/BUILDING WORKS

2.3 Construction Requirement

The measurement shall be recorded based on stages of works completed.

The following items shall be included in the administrative building.

Item Description Unit No

Desk with 3 drawers with locks for each plan No 1

Revolving Chairs with Tapestry Cushion No 1

3.1 REQUIREMENTS OF CONSTRUCTION DETAILS FOR OFFICE ROOM

8. The reinforced concrete roofs shall be made waterproof by application of an approved

3.2 Method of Measurement

4.1 Structural Concrete:

 Mineral Admixtures: Fly Ash conforming to Grade-I of IS: 3812

 Aggregates: Aggregates shall comply with requirements of IS: 383.The size of

 Water: Water as per Clause 5.4 of IS: 456 2000.

 Admixtures: Admixtures shall comply with IS: 9103

 Storage of Materials: Storage of Materials shall be as per IS: 4082

 Production of Concrete as per Clause 10 of IS: 456.

4.4 Statistical Field Check

4.10 Initial Curing

4.14 Method of Measurement

 Approximately every 3mt distance brick colums to be constructed of size 35x35cm

 Below FGL the thickness of Beam and Masonary will be 350mm.

5.1 Method of Measurement

The measurement shall be recorded based length of compound wall constructed.

The measurement shall be recorded based on stages of works completed.

7 THRUST BLOCK & PEDESTAL

8 ENCASING PIPE LINE.

Additional excavation required to be done shall be carried out as per instruction of

9.5 Method of Measurement

The measurement shall be recorded based on number of valve chamber constructed at

10 Road Crossing/Railway Crossing/Gas pipeline Crossings:

Measurement and Payment

 MDPE PIPE FOR PLOT SERVICE CONNECTIONS

SERVICE CONNECTIONS (PLOT SERVICE CONNECTIONS)-FERRULES AND STRAPS

SADDLE STRAP-FOR DI PIPES

 DUCTILE IRON PIPES

In particular, the following standards, specified herein shall be referred. In all

IS: 8329 Specification for Centrifugally Cast (spun) Ductile

DI pipes shall be systematically checked for any manufacturing defects by

experienced supervisors and a very high standard quality shall be maintained.

 All tests specified either in this specification or in the relevant Indian

 If the test is found unsatisfactory, Owner/Engineer may reject any or