2G BioEthanol-Civil and Structural Works Spec-BPCL-TCE

2G BIO ETHANOL REFINERY PROJECT
Bargarh, Odisha
TECHNICAL SPECIFICATIONS FOR CIVIL AND
STRUCTURAL WORKS
.
Doc No TCE.12282A-CV-3000-3001
Rev No R0 Date of Issue 26-07-2021
BHARAT PETROLEUM CORPORATION LTD
TCE.12282A-CV-3000-3001
TECHNICAL SPECIFICATIONS FOR
CIVIL AND STRUCTURAL WORKS
For
2G Bio Ethanol Refinery Project
Bargarh, Odisha, India
Rev. Date Doc Title:

ENGINEERING DESIGN BASIS FOR Prepared By Checked By Approved by
BUILDINGS
Initials Sign Initials Sign Initials Sign
26-07-
R0 Client: BHARAT PETROLEUM
2021 CORPORATION LTD
26-07- EPCM: TATA Consulting Engineers PPB

R0 Limited HSP JK
2021
Bargarh, Odisha
STRUCTURAL WORKS
.
Doc No TCE.12282A-CV-3000-3001
REVISION HISTORY
R0 ISSUED FOR APPROVAL HSP JK PPB 26-07-2021

REV DESCRIPTION PRPD BY CHKD BY APRD BY DATE
LEGENDS AND DETAILS:
Initials Name Organisation e-mail

HSP Himanshu Powar TCE hspowar@tce.co.in
JK J Karthikeyan TCE jkarthikeyan@tce.co.in
PPB Prashantsinh Bisen TCE ppbisen@tce.co.in
BPCL
BPCL
BPCL
Bargarh, Odisha
STRUCTURAL WORKS
.
Doc No TCE.12282A-CV-3000-3001
CHANGE LIST
Sr. No. Discipline Details of Change Reason of Change Remarks

1.
2.
3.
SPEC. NO. TATA CONSULTING ENGINEERS LIMITED SECTION: WRITE-UP
TCE. 12282A-CV-
3000-3001 STRUCTURAL WORKS
SHEET 1 OF 1
SPECIFICATION NO. TCE. 12282A-CV-3000-3001
TECHNICAL SPECIFICATIONS FOR
CIVIL AND STRUCTURAL WORKS
CLIENT : BHARAT PETROLEUM CORPORATION

LIMITED (BPCL)
PROJECT : PROPOSED CONSTRUCTION OF 2G BIO
ETHANOL REFINERY PROJECT
LOCATION : BARGARH, ODISHA
CONSULTANT : TATA CONSULTING ENGINEERS LIMITED
JOB NO. : TCE 12282A
FILE NAME: TCE.12282A-CV-3000-3001

Proprietary Notice and Version Control
This document contains confidential information for use only by the “Client”; for the Project under consideration, which is provided for the sole purpose of permitting the recipient to evaluate the information
submitted herewith. In consideration of receipt of this document; unless agreed to in contrary in the Contract; the recipient agrees to maintain such information in confidence and to not reproduce or otherwise
disclose this information to any person outside the recipient’s organisation; except that there is no obligation to maintain the confidentiality of any information which was known to the recipient prior to receipt of ISSUE
such information from Tata Consulting Engineers Limited, or becomes publicly known through no fault of recipient, or Tata Consulting Engineers Limited, or is received without obligation of confidentiality from a
third party owing no obligation of confidentiality to Tata Consulting Engineers Limited. All information given under this version over rides all and any kind of offers, assumptions, deliverables and contracts P0
submitted verbally (and subsequently communicated in writing) or in writing or otherwise given under any and all previous version/s.
FILE NAME: F-329-Rev-R7.docx TCE FORM NO. 329 R7

SPEC. NO.
TATA CONSULTING ENGINEERS LIMITED SECTION: WRITE-UP
TCE.12282A-CV- TECHNICAL SPECIFICATIONS FOR CIVIL AND
3000-3001 STRUCTURAL WORKS SHEET 1 OF 3
TECHNICAL SPECIFICATIONS


SPEC. NO.
TECHNICAL SPECIFIATIONS
SEC- SUB - SPECIFICATION NO OF
ISSUE TITLE
TION SECTION NUMBER SHEETS
TCE.12282A-CV-3000-
A A1 P0 SCOPE OF ENQUIRY 2
3001-01
B B1 TCE.12282A-CV-3000-
P0 PROJECT GENERAL INFORMATION 2
3001-02
F1 SCHEDULE OF DEVIATIONS FROM

TCE.M4-991 R8 1
F
F2 SCHEDULE OF EQUIPMENT AND
TCE.M4-994 R5 1
ERECTION MACHINERY
TCE.12282A-CV-3000- SPECIFIC TECHNICAL REQUIREMENTS
D1 P0 9
3001-03 DATA SHEET-A
D2 TCE.M4-418-01 EARTHWORK IN GRADING, EXCAVATION

R6 15
AND BACK FILLING
D3 TCE.M4-418-03 R3 DEWATERING 2
D4 TCE.M4-403-01 REINFORCED CONCRETE AND ALLIED

R11 40
WORKS
D5 TCE.M4-403-01-1 R5 GROUTING 6
D
D6 TCE.M4-405-01 SUPPLY AND FABRICATION OF
R9 28
STRUCTURAL STEEL
D7 TCE.M4-405-02 R9 ERECTION OF STRUCTURAL STEEL 14
D8 TCE.M4-405-04 SPECIFICATION FOR PAINTING OF

R7 16
STRUCTURAL STEEL
TCE.12282A-CV-3000-
D9 P0 RAINWATER DRAINAGE 1
3001-04
D10 TCE-M4-419-01 R4 GENERAL BUILDING WORKS 174
D11 TCE-M4-419-08 R4 ALUMINIUM FALSE CEILING 6
D12 TCE-M4-419-11 R5 ANTI-TERMITE TREATMENT IN BUILDING 5
D13 TCE-M4-419-12 R5 FALSE OR CAVITY WALL 9
D14 TCE-M4-419-14 R4 SPECIFICATIONS FOR FIREPROOF DOOR 9
WATER SUPPLY, SANITARY & DRAINAGE

D15 TCE-M4-435-06 R4 54
WORK


SPEC. NO.
SPECIFICATION FOR SHOT CRETING

D16 TCE.M4-403-06 R0 7
AND GUNITING
D SPECIFICATION FOR FIRE PROOFING OF
D17 TCE.M4-405-06 R0 6
STEEL STRUCTURES
NOTE 1: SECTION D IS GENERAL TECHNICAL SPECIFICATION CONSISTING OF MANY

ASPECTS. CONTRACTOR TO NOTE THAT ONLY THE CLAUSES RELEVANT TO THE PROJECT
SHALL BE CONSIDERED DURING PLANNING AT EXECUTION.
NOTE 2: ANNEXURE 1 IS AN EXHAUSTIVE LIST OF VENDORS. CONTRACTOR TO CONSIDER

ONLY THE RELEVENT ONES AS APPLICABLE FOR THE PROJECT.
NOTE 3: IN CASE OF PREFERENCES OF SPECIFICATIONS SELECTION,

SPECIFICATIONS/CONDITIONS MENTIONED IN THE SOR ( BOQ ) SHALL BE REFERRED AS
FIRST PRIORITY FOLLOWED BY SPECIFICATIONS MENTIONED IN THIS TECHNICAL
SPECIFICATION DOCUMENT/SCC/GCC AND THRID PRIORITY SHALL BE FOLLOWING DESIGN
BASIS REPORTS OF THIS PROJECT.


SPEC. NO. TATA CONSULTING ENGINEERS LIMITED SECTION: A1
TCE.12282A-CV-
3000-3001-01 SCOPE OF ENQUIRY SHEET 1 OF 2
1.0 INTRODUCTION
Bharat Petroleum Corporation Limited (BPCL) is a Government of India

Enterprise with a Maharashtra Status, a Forbes and Global Fortune 500
company, listed on the Bombay Stock exchange (BSE) and National Stock
Exchange (NSE), India. It is involved in the business of refining and
marketing of petroleum products in the country.
BPCL owns & operates four major refineries Mumbai Refinery, Kochi
Refinery and Bina Refinery. These produce a wide variety of petroleum fuels
& specialties.
BPCL now intends to install, a Second-Generation Ethanol Bio-refinery along
with Associated Facilities at Village Baulsingha, Bargarh, Odisha.
2.0 ABOUT SITE
The Site is divided in two parts comprising of an area of approximately

47.37(part 1) and 11.07(part 2) Acres respectively. Total 3 Nos of Gates are
installed in 1st part and 1 No. of Gate in 2nd part of the land.
Nearest Railway station is Bargarh which is situated at about 15 km from the
site and nearest airport is Jharsudguda which is about 110 km from the site.
3.0 SCOPE OF WORK
3.1 The scope of this enquiry shall comprise of but not limited to excavation and
backfilling, reinforced concrete works, steel structure and allied works for
plant / non-plant and allied buildings/ structures, drainage of plant building
and other areas, utilities and other buildings, equipment foundations, etc as
listed in below para including supplying, providing and furnishing of all
materials, equipment, plant, labour, transport, tools & tackles and all other
services necessary for the complete execution of works, including all
surveying and setting out necessary works.
3.2 The list of major buildings / facilities / structures covered under this enquiry
are listed below but not limited to:
Table 1 - List of Major buildings / facilities / structures
SR.NO STRUCTURES / EQUIPMENT
1. General Civil Works

1.1 CRWS Works
1.1.A Civil Works & CS Pipe Laying
2. Sheds
FILE NAME: TCE.12282A-CV-3000-3001-01

SPEC. NO. TATA CONSULTING ENGINEERS LIMITED SECTION: A1
TCE.12282A-CV-
3000-3001-01 SCOPE OF ENQUIRY SHEET 2 OF 2
2.1 Milling
2.1.A Civil Works & Structural works
2.2 Raw Water Tank Shed
2.3 Fire Water Tank Shed
3. Technological Structures & Piperacks

3.1 Evaporation Section
3.1.A Structural Works only
3.2 Distillation Section
3.2.A Structural Works only
3.3 Pre-Treatment Section
Civil & Structural Works (including deck slab but excluding side
3.3.A
cladding)
3.4 Co-Fermentation Section
3.4.A Civil & Structural Works
3.5 Solid Liquid Separation(Filter Press)
3.6 Piperacks
3.7 Pipe Bridges & Sleeper Racks
Note - Additional Scope or Changed scope other than scope mentioned
above may be allotted as per requirements provided by BPCL EIC. BOQ
item rates shall be followed for changed or added scope.
3.3 It is not the intent to specify completely herein all details of construction
activities. However, the work executed shall conform in all respects to high
standards of engineering design and workmanship and be capable of
performing in continuous commercial operation in a manner acceptable to the
ENGINEER/OWNER who will interpret the meaning of drawings and
specifications and shall have the power to reject any work or materials which
in his judgement are not in full accordance therewith.
FILE NAME: TCE.12282A-CV-3000-3001-01


SPEC. NO. TATA CONSULTING ENGINEERS LIMITED SECTION: B1
TCE.12282A-CV-
3000-3001-02 PROJECT GENERAL INFORMATION SHEET 1 OF 1
BHARAT PETROLEUM CORPORATION

1. Owner / Purchaser
LIMITED (BPCL)
TATA Consulting Engineer Limited,

2. EPCM
Mumbai
PACKAGE II – CIVIL, STRUCTURAL

3. Project Title
AND ARCHITECTURAL WORKS
4. Location Bargarh, Odisha
Nearest City Jharsuguda
5. Site elevation 3.00 M above MSL
6.0 Transport Road & Railway
6.1 Railway
Nearest Railway Station Bargarh
Well connected with cities Raipur &

6.2 Road
Jharsudguda
6.3 Air Port Jharsuguda
6.4 Sea Port Nearest is Dhamra Port
7.0 Wind Data
a) Basic Wind Speed 44 m/s as per IS: 875(Part-3)
8.0 Seismic Data
a) Zone Zone II as per IS: 1893(Part-1)
FILE NAME: TCE.12282A-CV-3000-3001-02

such information from Tata Consulting Engineers Limited, or becomes publicly known through no fault of recipient, or Tata Consulting Engineers Limited, or is received without obligation of confidential ity from a
TATA CONSULTING ENGINEERS LIMITED SECTION: F
SPEC. NO
TCE.M4-991 SCHEDULE OF DEVIATIONS FROM
SHEET 1 OF 1
The BIDDER shall indicate below all deviations from the Technical Specifications.
SL.
SECTION SPECIFICATION NO. PARA NO. DEVIATION
NO.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
The BIDDER hereby certifies that the above mentioned are the only deviations from the
PURCHASER’s/CONSULTANT’s Technical Specifications for this Enquiry Document. The
BIDDER further confirms that in the event any other data and information presented in the
BIDDER’s proposal and accompanying documents including drawings and catalogues etc. are
at variance with the specific requirements laid out in the PURCHASER’s/CONSULTANT’s
Technical Specifications, the latter shall govern and shall be binding on the BIDDER without any
price implication.
COMPANY SEAL SIGNATURE

NAME
DESIGNATION
COMPANY
DATE
ISSUE
R8
FILE NAME: M4991R8.DOC TCE FORM NO. 329 R5

TATA CONSULTING ENGINEERS LIMITED SECTION: F
SPEC. NO
TCE.M4-994 SCHEDULE OF EQUIPMENT AND ERECTION SHEET 1 OF 1
MACHINERY
The BIDDER shall indicate below the equipment and erection machinery he has in his
possession and proposes to bring to the site, in case the work is awarded to him.
SL.
TYPE AND DESCRIPTION OF THE EQUIPMENT NUMBER IN NUMBER
NO.
AND ERECTION MACHINERY POSSESSION PROPOSED
TO BRING TO
THE SITE
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
The BIDDER hereby confirms that the quantity and type of equipment and erection machinery
he will employ for the site work will not be less than those listed above. The BIDDER also
agrees to bring more equipment and erection machinery, if so warranted, in the opinion of the
PURCHASER/ CONSULTANT to meet the construction norms and construction schedule.
COMPANY SEAL SIGNATURE

NAME
DESIGNATION
COMPANY
DATE
ISSUE
R5
FILE NAME: M4994R5.DOC TCE FORM NO. 329 R5

SPEC. NO. TATA CONSULTING ENGINEERS LIMITED SECTION: D1
TCE.12282A-CV-
3000-3001-03 SPECIFIC TECHNICAL REQUIREMENTS – DATA SHEET - A SHEET 1 OF 9
1. SCOPE
1.1. The specification covers the general requirements and the specific technical
requirements for the works, which are not covered by any of the other
component specifications of Section D but are required to be carried out for
the satisfactory completion of the work. This specification and the other
component technical specifications contained in Section D are mutually
dependent and essential for correct interpretation of the contract. If the
requirements of this section and the other technical specifications in Section
D conflict, those of this section shall govern. Bidder shall bring out such
variations to Owner / Engineer-in-charge's notice for seeking clarifications. It
shall be noted that all Codes of Practice and Standards shall be those of
latest issue.
1.2. It shall be very clearly understood that the specifications given in Section D
are brief and do not cover minute details. However, all works shall have to be
carried out in accordance with the relevant standards and codes of practices
or in their absence in accordance with the best accepted current engineering
practices or as directed by Engineer from time to time. Items for which
separate specifications have not been indicated shall be carried out in
consultation with and as directed/approved by Engineer. The decision of
Engineer as regards the specification to be adopted and their interpretation
and the mode of execution of work shall be final and binding on Contractor
and no claim whatsoever shall be entertained on this account.
2. SUB-SOIL DATA
2.1. The Geotechnical Investigation report will be made available to the successful
bidder at the time of mobilisation by Owner. However, Bidder is advised to
visit the site and get acquainted with the site conditions such as type of soil
etc.
3. SITE GRADING
Earthwork in filling with borrow earth or excavated earth for site grading over
areas, banking excavated earth in layers not exceeding 150 mm in depth to
lines, levels and profiles indicated by Engineer and compacting including all
leads and lifts and spreading to level, rolling at OMC using vibratory power
roller of 8-10 tonne static weight to achieve not less than 95% Modified
Proctor Density including dressing up the peripheral embankments of the area
to be filled up, lead up to 1 KM, in all types of soil except soft/decomposed
and hard rock for all lifts or depths up to 1 m above or below the average
ground level (The average ground level shall be fixed by Engineer prior to
start of work).
4. EXCAVATION
4.1. Excavation for foundations, substructures, trenches, sumps, tunnels, pits etc.
in all types of ordinary and hard soils including all types of murum, with
necessary shoring, strutting, stacking selected material for backfilling or
FILE NAME: TCE.12282A-CV-3000-3001-03
submitted herewith. In consideration of receipt of this document; unless agreed to in contrary in the Contract; the recipient agrees to maintain such information in confidence and to not reproduce or
otherwise disclose this information to any person outside the recipient’s organisation; except that there is no obligation to maintain the confidentiality of any information which was known to the recipient prior
ISSUE
to receipt of such information from Tata Consulting Engineers Limited, or becomes publicly known through no fault of recipient, or Tata Consulting Engineers Limited, or is received without obligation of
confidentiality from a third party owing no obligation of confidentiality to Tata Consulting Engineers Limited. All information given under this version over rides all and any kind of offers, assumptions,
P0
deliverables and contracts submitted verbally (and subsequently communicated in writing) or in writing or otherwise given under any and all previous version/s.

TCE.12282A-CV-
disposing excess excavated material anywhere in the plot area, for following
depths measured from the average ground level including dewatering etc
complete. (Excavation / removal of rubble fill shall be paid under this item)
(The average ground level shall be fixed by Engineer prior to start of work)
5. CONCRETE
5.1. Factory blended Portland Pozzolona Cement ( 28 days strength shall be 43

N/mm2 ) shall be used for all concrete works. Contractor shall make all the
arrangements related to activities of unloading, stacking and storing in shed
at its own cost. Contractor shall make available adequate shuttering and
staging materials, due to longer setting time of PPC, as directed by
Engineer/Owner. No delays and extra claims shall be entertained on this
account.
5.2. Contractor shall make temporary arrangement for storage of the Cement at
his own cost. The location for this storage shall be as directed by
Engineer/Owner.
5.3. The structural grade of concrete shall be of minimum M25 Grade having
minimum cement content as per IS:456-2000 shall be used using 20mm
and downsize graded crushed stone aggregate with maximum water
cement ratio of 0.5. Water-reducing admixtures conforming to IS 9103
(Latest Edition) shall be used for all structures.
5.4. RCC to be used for grade slab inside enclosed buildings, paving area &
drainages shall be of grade M25.
5.5. Unless otherwise specified minimum grade of RCC to be used for Liquid
retaining structures and its foundations shall be M30 confirming to IS:456 shall
be used using 20mm and downsize graded crushed stone aggregate.
5.6. Unless otherwise specified 75mm thick PCC 1:2:4 of M7.5 grade by weight using
20mm and downsize graded crushed stone aggregate shall be provided under all
RCC foundations. The PCC concrete shall extend 75mm beyond foundations.
5.7. Unless otherwise specified plum concrete of grade M5 using 40mm and
downsize grade crushed stone aggregate shall be used as filler material wherever
loose subgrade exists by removing the loose soil/fill
5.8. Design mix for grade M7.5, M20, M25 & M30 shall be prepared by the
contractor in the beginning of the civil construction work at site. The design mix
shall be prepared for each grade with and without admixtures. Moreover, the
fresh design mix shall also be prepared at every change of sources of sand,
aggregates and cement.
5.9. Contractor shall take special care for concrete for liquid retaining structures,
underground structures and those others specifically called for to guarantee
FILE NAME: TCE.12282A-CV-3000-3001-03

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TCE.12282A-CV-
the finish and water tightness. All such structures shall be hydro-tested.
Contractor shall include in his price hydro-testing of structure including all
arrangements for testing such as temporary bulk heads, pressure gauges,
pumps, pipe lines, etc. Any temporary arrangements that may have to be
made to ensure stability of the structure shall also be considered by the
bidder in his price while quoting the rates. Any leakage that may occur during
the hydro-test or subsequently during the defects liability period or the period
for which the structure is guaranteed shall be effectively stopped either by
cement/epoxy pressure grouting, geniting or such other method as may be
approved by Engineer. All such rectification shall be done by Contractor to the
entire satisfaction of Owner/Engineer at no extra cost to Owner.
5.10. Contractor shall design the mix for concrete for all the types of grades
required for civil works, with and without admixtures. The concrete mix
design report shall be got approved from the Engineer-in-charge / Owner,
prior to start of the work.
5.11. The contractor shall install and deploy the batching plant of adequate
capacity. Adequate nos. of diesel operated concrete pumps and adequate
numbers of transit mixers shall be deployed by the contractor at site.
5.12. Adequate arrangements shall be made to make the area clear from boring
muck / slushy / surplus earth.
5.13. All R.C.C. of designed grade shall be provided at all heights and levels on
well compacted / sound surfaces including dewatering, shuttering, vibrating,
curing and finishing as required. Integral water-proofing compound shall be
added @ 2% by weight of cement in the wet concrete for the specified area in
the drawings.
5.14. Concrete in contact with earth shall be given two coats of bituminous paint.
6. REINFORCEMENT
6.1. Grade of reinforcement shall be High strength Deformed Thermo

mechanically treated (TMT) steel bars of grade Fe500D having elongation
more than 14.5 percent and confirming to other requirements of IS 1786.
6.2. Contractor shall prepare detail bar bending schedule based on design
drawings furnished by Engineer.
7. STRUCTURAL STEEL WORKS

7.1. Structural steel shall be E250/E275 grade, Quality A/BR, semi killed/killed and
conforming to IS: 2062 where V-notch energy E>27J unless noted.
7.2. Plates shall be E250 grade, Quality A/BR, killed, tested for impact resistance
and confirming to IS 2062 unless noted. Plates beyond 12mm and up to
40mm thickness shall be controlled rolling. Plates beyond 40mm thickness
FILE NAME: TCE.12282A-CV-3000-3001-03
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TCE.12282A-CV-
shall be normalizing rolling and shall be ultrasonically tested as per ASTM-

A578 level B-S2.
7.3. Anchor Bolts shall be turned from M.S. rounds conforming to IS 2062 Grade-
A (Class-4.6).
7.4. Nuts Shall conform to IS 1363
7.5. Threading shall be coarse conforming to IS 1367 and IS 4218.f Sleeve shall
be M.S Tubes (Medium) as per IS 1239.
7.6. Washers shall conform to IS 2016.
7.7. Stiffeners shall conform to IS 2062 Grade-A or Grade-B.
7.8. MS Chequered plates confirming to IS: 3502 :2009 (Reaffirmed 2015).
7.9. Mass of hot dipped galvanised grating should be min. 610gm/m2 conforming
to IS code 4759.
8. CONCRETE SURFACE FINISH
8.1. Concrete surfaces shall not be plastered unless otherwise shown on the
drawings or directed by Engineer. The concrete surfaces above ground shall
be of high-quality stain free, smooth and even with no shutter marks.
Approved shutter/mould release agents shall be used. However, Engineer's
approval shall not relieve Contractor of his contractual obligations and his
responsibilities for ensuring and providing the finish specified or removing/
rectifying defective work.
8.2. The grade slab in all buildings shall have even surface with all necessary
levelling. The concrete shall be finished with vacuum dewatering and
mechanical trowelling to render even surface.
8.3. Form-work (Straight or Curved) for concrete items shall include forming
chamfers, drip moulds, pockets, scaffolding, centring, finishing concrete
surface after striking the form-work etc.
8.4. Tubular staging (ACROW or equivalent) is to be used for all structural / RCC
work for all floors at all levels and heights. Aluminium / Wooden / Steel forms
shuttering shall be used for all surfaces. For beam sides, wooden shuttering
may be used. The rate quoted for formwork and shuttering shall remain
applicable irrespective of the material used. Contractor can use any material
to expedite the work. No extra cost will be paid.
8.5. Mould release agents shall be used for all shuttering. Approval of make/brand
of mould release agents shall be obtained from Engineer prior to use in
works.
FILE NAME: TCE.12282A-CV-3000-3001-03

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TCE.12282A-CV-
9. BITUMEN – SAND MIX LAYER
9.1. Material for the finish layer of ring wall tank shall normally be hot bitumen -
sand mix in the following proportions by weight:
▪ 48% stone, size range of 3-6 mm.

▪ 45% sand of good gradation.
▪ 7% mineral filler, limestone or dolomite dust with 80% passing 0.075 mm
sieve or local approved alternative (not cement).
▪ 7.5% nontoxic cut-back bitumen, grade Shelmac 80/100 (recommended
mixing temperature 65-95°C) to be added to the composite mixture above
and shall comply with the requirements of IS:217.
Above mixture shall have a good stability and a rational flow of bitumen
adopting the qualification of the layer to the profile of the tank (bottom). Low
percentage of voids in the mixture, after rolling, to be left and an adequate
guarantee on water tightness is provided.
10. WATERPROOFING TREATMENT TO R.C.C. TERRACE SLAB
10.1. Water-proofing treatment to RCC terrace slab shall be done applying two
coats of POLYALK WP of M/s Sunanda Specialty Coatings Pvt. Ltd. or
equivalent and cement in proportion as recommended by manufacturer. The
procedure for surface preparation and final application shall be as
recommended by manufacturer.
10.2. Brick bat Coba in cement mortar 1:3 shall be provided to proper level and
slope having average thick of 115 mm. Curing shall be done with filling of
water for 48 hrs. The top surface shall be finished with IPS flooring including
making rounding at corners and at the junction of wall and floor. Final
inspection shall be carried out to ensure that there are no damp patches,
leakages, seepages etc at lower slab. If any type of leakages, seepages,
damp patches are found, same shall be repaired to Owner / Engineer-in-
charge’s satisfaction at contractor’s own cost.
10.3. The waterproofing treatment is to be guaranteed for bone dry condition for a
period of 10 years.
10.4. The application of water-proofing shall be by approved applicators of the

manufacturer.
11. WATERPROOFING TREATMENT TO TOILETS / KITCHEN FLOOR
11.1. Water-proofing treatment shall be done by applying two coats of POLYALK

WP of M/s Sunanda Specialty Coatings Pvt. Ltd. or equivalent and cement in
FILE NAME: TCE.12282A-CV-3000-3001-03
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TCE.12282A-CV-
proportion as recommended by manufacturer. The procedure for surface

preparation and final application shall be as recommended by manufacturer.
Provide wet coat of 1:4 cement mortar of 15-20 mm thickness and shall be
thoroughly cured with 6” rounding at corners by filling water for 3 days to
receive a final layer of brick bat.
11.2. The 4½” thick soaked brick bat coba shall be provided in C:M 1:3 to proper
level and slope. Curing shall be done by filling water for 48 hrs. Concrete
screed shall be laid over a brick bats with 10mm downgraded aggregates by
adding proportionate dosage “SUNPLEX” of M/s Sunanda Specialty Coatings
Pvt. Ltd. or equivalent as recommended by manufacturer. Surface shall be
kept rough for further tiling work. Curing shall be done for minimum 7 days by
filling water. Final inspection shall be carried out to ensure that there are no
damp patches, leakages, seepages etc. If any type of leakages, seepages
damp patches are found, same shall be repaired to Owner / Engineer-in-
charge’s satisfaction at contractor’s own cost.
period of 10 years.
11.4. The application of water-proofing shall be by approved applicators of

manufacturer.
12. WATERPROOFING TREATMENT TO LIQUID RETAINING STRUCTURES
12.1. Water-proofing treatment shall be done applying two coats of POLYALK WP

of M/s Sunanda Specialty Coatings Pvt. Ltd. or equivalent and cement in
proportion as recommended by manufacturer. The procedure for surface
preparation and final application shall be as recommended by manufacturer.
12.2. A single coat of bonding agent HACK-AID-PLAST of M/s. Sunanda Specialty

Coatings Pvt. Ltd. or equivalent shall be applied as per manufacturer’s
recommendation. Provide wet a base coat of 1:4 cement mortar in 10-12 mm
thickness and cure for 3 days with filled water as per manufacturer’s
specifications. If any type of leakages, seepages damp patches are found,
same shall be repaired to Owner / Engineer-in-charge’s satisfaction at
contractor’s own cost.
period of 10 years.
12.4. The application of water-proofing shall be by approved applicators of

manufacturer.
13. WATERPROOFING TREATMENT TO UNDERGROUND PITS, SUMPS,

TRENCHES, BASEMENTS, ETC.
13.1. Waterproofing treatment of base by external tanking method, for Basement,

Lift Pits, Trenches & other underground structures during construction,
consisting of cement slurry mixed with approved acrylic waterproof
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compound, 25mm thick bedding layer of CM 1:3, Shahabad stone of 20-25

mm thick well pointed in the joints with cement & approved acrylic
waterproofing compound, as per manufacturer's specifications and finished
smooth with 25mm thick CM not leaner than 1:4 ( The total thickness of the
treatment shall be about 75 mm), and continuing the treatment on the side
walls, including the cost of all materials, labour, tools and tackles and
processes all as required, as per specifications and as directed complete.
13.2. Waterproofing treatment on the outer face of walls by external tanking

method, up to a height of 300 mm above adjacent finished ground level,
consisting of 15mm thk cement backing mixed with approved acrylic
waterproof compound, 20-25mm thk Shahabad stone finished with 15mm thk
CM not leaner than cement mortar1:4 mixed with acrylic waterproof
compound (The total thickness of water-proofing treatment shall be about
55mm), including the cost of all materials, labour, tools and tackles and
processes all as required, as per specifications and as directed complete.
13.3. Waterproofing of walls shall be done only after hydro testing of Vaults is
completed.
13.4. A working space of about 600 mm shall have to be provided in the excavation
separately for treatment of exterior faces of walls.
period of 10 years.
14. TESTING STRUCTURES FOR LEAKAGE
14.1. Hydro-static test for water tightness shall be done at full storage level as
described below:
14.1.1. In case of structures whose external faces are exposed, such as water tanks,
the requirements of the test shall be deemed to be satisfied if the external
faces show no sign of leakage or sweating and remain completely dry during
the period of observation of seven days after allowing a seven (07) days
period for absorption after filling with water.
14.1.2. In the case of structures whose external faces are submerged and are not
accessible for inspection, such as underground tanks, the structures shall be
filled with water for seven (07) days. After the expiry of seven days, the level
of the surface of the water shall be recorded. The level of water shall be
recorded again at subsequent intervals of 24 hours over a period of seven
days. Backfilling shall be withheld till the tanks are tested. The total drop in
surface level over a period of seven days shall be taken as an indication of
the water tightness of the structure. Engineer shall decide on the actual
permissible nature of this drop in the surface level, taking into account
whether the structures are open or closed and the corresponding effect it has
on evaporation losses. Unless specified otherwise, a structure whose top is
covered shall be deemed to be water tight if the total drop in the surface level
over a period of seven days does not exceed 40 mm.
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14.1.3. Each compartment/segment of the structure shall be tested individually and

then all together.
15. CHAJJAS, SLAB & SILL PROJECTIONS
15.1. All chajjas, slab and sill projections shall be provided with drip mould and/or
throating.
16. EXPANSION JOINTS AND SEALANTS
16.1. All the expansion joints (except joints in concrete paving) shall be filled
"Shalitex" board of required thickness as per the drawings including sealing
with Two part pour grade type Poly-sulphide based sealant as per BS : 254
("PIDISEAL PS-42P" of Pidilite or approved equivalent) shall be used in
expansion joints or at places as indicated in drawings or as specified the
Engineer-in-charge including surface preparation, primer, masking tapes,
backer rod of polyethylene foam etc., as per manufacturer's specifications.
16.2. Bituminous sealants shall be used in expansion / construction joints in

concrete paving or as indicated on the drawing.
16.3. Sealant to be used in floor cracks etc. shall be "Sunexpoxy 358" of Sunanda
Speciality Coatings Pvt. Ltd. Or Ciba-Geigy Araldite GY257 with hardener
HY840 or equivalent. The application shall be as per manufacturer's
specifications and as directed by Engineer in places specified or as shown
on the drawings or as directed on the site.
17. PLUMBING
17.1. All works shall be executed through approved licensed plumbers.
17.2. Based on design drawings indicating locations of floor drains, traps, sanitary
and water supply fixtures, Contractor shall prepare detailed working drawings
indicating the position of fittings, valves joints, supports, connection to main
lines, manholes, inspection chambers, sumps, septic tanks, etc. These
drawings shall be made by a licensed plumber in Contractor's employment or
otherwise and duly signed by him. The correctness of the drawings shall be
the responsibility of Contractor. No work shall be commenced unless the
drawings are approved by Engineer and / or statutory authorities.
17.3. HDPE pipes shall confirm to IS 14333 PE 80 grade.
18. FLOORING
18.1. Laying of tiles shall start from the centre of the room and proceed towards the
ends. Equal sizes of cut tiles shall be provided near the walls of each room.
Tiles shall be sorted before laying so that each area / room has only one
shade.
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18.2. Kota stone tiles shall conform to IS:3622 - Specification for sand stone (slabs
and tiles).
19. DRAINAGE OF RAIN WATER IN EXCAVATED AREAS
19.1. Grading in the vicinity of excavation shall be such as to exclude rain / surface-
water draining into excavated areas. Excavation shall be kept clean of rain
and such water as the Contractor may be using for his work by suitably
pumping out the same at no extra cost to the owner. The scheme for pumping
and discharge of such water shall be approved by the Engineer.
19.2. Contractor shall ensure that the surface runoff outside the excavated pit
/working area shall be collected through a catch water drain excavated
around the working area and led away to a natural stream, at no extra cost to
the owner. Contractor shall maintain the catch water drains in proper
condition during the construction period at no extra cost to the owner.
19.3. The contractor shall be entirely responsible for the provision and the
maintenance of efficient drainage arrangements in the work site to lead off
all water whatever pumped from the excavation or on account of rains,
springs or any other source whatsoever. Flooding or ponding of water in
the work site shall not be permitted under any circumstances whatsoever and
the contractor shall take all precautions to prevent the same by
providing suitable pump and other dewatering arrangements. The cost
of repairing damages, if any to the work under execution or to any
Government property in and around the site shall be entirely borne by the
contractor, when such damages are due to his non-compliance with the above
conditions.
20. FALSE / RAISED / CAVITY FLOORING (Except for Electrical Substations

& MCC Rooms)
The raised floor system of "DG Floor" or equivalent, to be installed shall

have finished floor height of 600 mm to 1200 mm from the existing floor
level. The system shall provide for suitable pedestal and under-structure
design to withstand various static loads and rolling loads subjected to it in
an office / DCS /server / Panel etc. The entire raised floor system can be
providing for adequate acoustic barrier, air leakage and fire resistance.
The system shall be able to accept, approved laminated floor covering
anti-static PVC / Anti-Static Laminate and PVC beading on all sides of the
panel. The overall system shall be able to withstand a UDL of 1080 kgs
perSq.mt. and a point load of 360 kgs.
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TCE.M4-418-01 EARTHWORK IN GRADING, EXCAVATION
SHEET 1 OF 15
AND BACKFILLING
1.0 SCOPE
This specification covers the general requirements of earthwork in excavation for
different types of soil, site grading, filling in areas as shown in drawing, backfilling
around foundations and in plinths, conveyance and disposal of surplus soils or
stacking them properly as shown in the drawings and as directed by the ENGINEER
and all operations covered within the intent and purpose of this specification.
2.0 APPLICABLE CODES
The following Indian Standard Codes, unless otherwise specified herein, shall be
applicable. In all cases, the latest revision of the codes shall be referred to.
1. IS 456: 2000 - Code of practice for plain and reinforced
(Reaffirmed 2016) concrete.
2. IS 783: 1985 - Code of practice for laying of concrete pipes.

(Reaffirmed 2017)
3. IS 1200: 1992 - Method of measurement of Building and Civil
Engineering works.
Part 1 (Reaffirmed Part 1 Earthwork.
2017)
Part 27 (Reaffirmed Part 27 Earthwork done by mechanical
2018) appliances.
4. IS 1498: 1970 - Classification and Identification of Soils for
(Reaffirmed 2016) General Engineering purposes.
5. IS 3764: 1992 - Excavation work-code of safety.
(Reaffirmed 2017)
6. IS 2720 - Methods of test for soils:
Part 1: 1983 - Preparation of dry soil samples for various
(Reaffirmed 2015) tests.
Part 2: 1973 - Determination of water content.
(Reaffirmed 2015)
Part 4: 1985 - Grain size analysis.
(Reaffirmed 2015)
Part 5: 1985 - Determination of liquid and plastic limit.
(Reaffirmed 2015)
Part 7: 1980 - Determination of water content - dry density
(Reaffirmed 2016) relation using light compaction.
Part 9: 1992 - Determination of dry density - moisture
(Reaffirmed 2016) content relation by constant weight of soil
method.
Part 14: 1983 - Determination of density index (relative
(Reaffirmed 2015) density) of cohesionless soils.
Proprietary rights of the information contained herein belong to Tata Consulting Engineers Limited (TCE).
This information is intended to be used for the mentioned purpose/project only. In case of misuse of information
and any claim arising thereof, cost and consequence will be on the party misusing the information.
FILE NAME: M4-418-01-Rev-R6.docx TCE FORM NO. 329 R7

SHEET 2 OF 15
AND BACKFILLING
Part 28: 1974 - Determination of dry density of soils in place,

(Reaffirmed 2015) by the sand replacement method.
Part 33: 1971 - Determination of the density in place by the

(Reaffirmed 2015) ring and water replacement method.
Part 34: 1972 - Determination of density of soil in place by
(Reaffirmed 2015) rubber balloon method.
Part 38: 1976 - Compaction control test (HILF Method).
(Reaffirmed 2016)
7. IS 4081: 2013 - Safety Code for Blasting and related Drilling
(Reaffirmed 2018) Operations.
3.0 DRAWINGS
The ENGINEER will furnish drawings wherever, in his opinion, such drawings are
required to show areas to be excavated / filled up to grade level, sequence of
priorities, etc. The CONTRACTOR shall strictly follow such drawings.
4.0 GENERAL
The CONTRACTOR shall furnish all tools, plants, instruments, qualified supervisory
personnel, labour, materials any temporary works, consumables, any and everything
necessary, whether such items are specifically stated herein or not, for completion
of the job, in accordance with the specification requirements.
The CONTRACTOR shall carry out the survey of the site before excavation and set
properly all lines and establish levels for various works such as earthwork in
excavation for grading, basement, foundations, plinth filling, roads, drains, cable
trenches, pipelines, etc. Such survey shall be carried out by taking accurate cross
sections of the area perpendicular to established reference/ grid lines at 8 m intervals
or nearer as determined by the ENGINEER based on ground profile. These shall be
checked by the ENGINEER and thereafter properly recorded.
The excavation shall be done to correct lines and levels. This shall also include,
where required, proper shoring to maintain excavations and also the furnishing,
erecting and maintaining of substantial barricades around excavated areas and
warning lamps at night for ensuring safety.
The rates quoted shall also include for dumping of excavated materials in regular
heaps, bunds, riprap with regular slopes as directed by the ENGINEER, within the
lead specified and levelling the same to provide natural drainage. Rock/ soil
excavated shall be stacked properly as directed by the ENGINEER. As a rule, all
softer material shall be laid along the centre of heaps, the harder and more weather
resisting materials forming the casing on the sides and the top. Rock shall be stacked
separately.
5.0 CLEARING
The area to be excavated/ filled shall be cleared of fences, trees, plants, logs,
stumps, bush, vegetation, rubbish, slush, etc. and other objectionable matter. If any
roots or stumps of trees are met during excavation, they shall also be removed. The

SHEET 3 OF 15
AND BACKFILLING
material so removed shall be burnt or disposed of as directed by the ENGINEER.

Where earth fill is intended, the area shall be stripped of all loose/ soft patches, top
soil containing objectionable matter/ materials before fill commences.
6.0 PRECIOUS OBJECTS, RELICS, OBJECTS OF ANTIQUITY, ETC.
All gold, silver, oil, minerals, archaeological and other findings of importance, trees
cut or other materials of any description and all precious stones, coins, treasures,
relics, antiquities and other similar things which may be found in or upon the site
shall be the property of the OWNER and the CONTRACTOR shall duly preserve the
same to the satisfaction of the OWNER and from time to time deliver the same to
such person or persons as the OWNER may from time to time authorise or appoint
to receive the same.
7.0 CLASSIFICATION
All materials to be excavated shall be classified by the ENGINEER, into one of the
following classes and shall be paid for at the rate tendered for that particular class
of material. No distinction shall be made whether the material is dry, moist or wet.
The decision of the ENGINEER regarding the classification of the material shall be
final and binding on the CONTRACTOR and not be a subject matter of any appeal
or arbitration.
Any earthwork will be classified under any of the following categories:
(a) Ordinary and Hard Soils
These shall include all kinds of soils containing kankar, sand, silt, murrum
and/ or shingle, gravel, clay, loam, peat, ash, shale, etc., which can generally
be excavated by spade, pick axes and shovel, and which is not classified
under "Soft and Decomposed Rock" and "Hard Rock" defined below. This
shall also include embedded rock boulders not longer than 1 metre in any one
direction and not more than 200 mm in any one of the other two directions.
(b) Soft and Decomposed Rock
This shall include highly fractured rock, boulders, slag, chalk, slate, hard mica
schist, laterite and all other materials, which in the opinion of ENGINEER is
rock, but does not need blasting and could be removed with picks, hammer,
crow bars, wedges, and pneumatic breaking equipment. The mere fact that
the CONTRACTOR resorts to blasting for reasons of his own, shall not qualify
for classification under 'Hard Rock'.
This shall also include excavation in macadam and tarred roads and
pavements. This shall also include rock boulders not longer than 1 metre in
any direction and not more than 500 mm in any one of the other two
directions. Masonry to be dismantled will also be measured under this item.
(c) Hard Rock
This shall include all rock occurring in large continuous masses, which cannot
be removed except by blasting for loosening it. Harder varieties of rock with
or without veins and secondary minerals, which in the opinion of the

SHEET 4 OF 15
AND BACKFILLING
ENGINEER require blasting shall be considered as hard rock. Where hard

rock is met with and blasting operations are not permitted, the
CONTRACTOR shall use other methods such as use of chemicals or any
other method approved by the ENGINEER for loosening the rock mass,
developing cracks, etc. The loosened material shall be thereafter removed
either by mechanical means or manually. Boulders of rock occurring in such
sizes and not classified under (a) and (b) above shall also be classified as
hard rock. Concrete work both reinforced and unreinforced to be dismantled
will be measured under this item, unless a separate provision is made in the
Schedule of Quantities.
8.0 EXCAVATION
All excavation works shall be carried out by mechanical equipment unless, in the
opinion of the ENGINEER, the work involved, and the time schedule permit manual
work and separate item is provided in the bill of quantities. Excavation for permanent
work shall be taken out to such widths, lengths, depths and profiles as are shown in
the drawings or such other lines and grades as may be specified by the ENGINEER.
Rough excavation shall be carried out to a depth 150 mm above the final level. The
balance shall be excavated with special care. Soft pockets shall be removed even
below the final level and extra excavation filled up as directed by the ENGINEER.
The final excavation if so instructed by the ENGINEER, should be carried out just
prior to laying the mud-mat.
The CONTRACTOR may, for facility of work or similar other reasons excavate, and
also backfill later, if so approved by the ENGINEER, at his own cost outside the lines
shown in the drawings or directed by the ENGINEER. Should any excavation be
taken below the specified elevations, the CONTRACTOR shall fill it up, with concrete
of the same class as in the foundation resting thereon, upto the required elevation.
No extra cost shall be claimed by the CONTRACTOR on this account.
All excavation works shall be done to the minimum dimensions as required for safety
and working facility. Prior approval of the ENGINEER shall be obtained by the
CONTRACTOR in each individual case, for the method he proposes to adopt for the
excavation, including dimensions, side slopes, dewatering, disposal, etc. This
approval, however, shall not in any way relieve the CONTRACTOR of his
responsibility for any consequent loss or damage. The excavation must be carried
out in the most expeditious and efficient manner. Side slopes shall be as steep as
will stand safely for the actual soil conditions encountered. Every precaution shall be
taken to prevent slips. Should slips occur, the slipped material shall be removed, and
the slope dressed to a modified stable slope. Removal of the slipped earth will not
be paid for if the slips are due to the negligence of the CONTRACTOR.
Excavation shall be carried out with such tools, tackles and equipment as described
herein before. Blasting or other methods may be resorted to in the case of hard rock
only with the specific permission of the ENGINEER.

SHEET 5 OF 15
AND BACKFILLING
9.0 STRIPPING LOOSE ROCK

All loose boulders, semi-detached rocks (along with earthy stuff, which might move
therewith) not directly in the excavation but so close to the area to be excavated as
to be liable, in the opinion of the ENGINEER, to fall or otherwise endanger the
workmen, equipment, or the work, etc., shall be stripped off and removed away from
the area of the excavation. The method used shall be such as not to shatter or render
unstable or unsafe the portion, which was originally sound and safe.
Any material not requiring removal as contemplated in the work, but which, in the
opinion of the ENGINEER, is likely to become loose or unstable later, shall also be
promptly and satisfactorily removed as directed by the ENGINEER. The cost of such
stripping will be paid for at the unit rates accepted for the class of materials in
question.
10.0 EARTHWORK IN EXCAVATION FOR MAJOR EXCAVATION (BASEMENTS/
RETAINING WALLS)
Excavation shall be undertaken to the width of the Basement/ Retaining Wall Raft/
Footing including necessary margins for construction operation as per drawing or as
directed by the ENGINEER. Where the nature of soil or the depth of the trench and
season of the year do not permit vertical sides, the CONTRACTOR shall, at his own
expense, put up the necessary shoring, strutting and planking or cut slopes with or
without steps, to a safer angle or both with due regard to the safety of personnel and
works and to the satisfaction of the ENGINEER. The scheme proposed by the
CONTRACTOR shall take into consideration the presence of existing buildings/
structures in the vicinity, if any.
All the major excavation shall be carried out by mechanical excavator. No extra
payment shall be made for that.
The CONTRACTOR shall make, at his own cost, all necessary arrangements for
maintaining water level, in the area where works are under execution low enough so
as not to cause any harm to the work. These shall be considered as inclusive of
pumping out or bailing out water, if required, for which no extra payment shall be
made. This will include water coming from any source such as rains, accumulated
rain water, floods, leakages from sewer and water mains, water ingress from nearby
nallah, subsoil water table being high or due to any other cause whatsoever. The
CONTRACTOR shall make necessary provision of pumping, dredging, bailing out
water coming from all above sources and excavation and other works shall be kept
free of water by providing a suitable system approved by the ENGINEER.
In order to avoid possibility of basement raft of building getting uplifted/ damaged
due to water pressure, the CONTRACTOR shall lower the ground water table below
the proposed foundation level by boring tube wells all around the proposed building
using well point sinking method or any suitable method as approved by the
ENGINEER. Sub soil water table shall be maintained at least 500mm below the layer
of blinding concrete (Plain Cement Concrete (PCC)) level during laying of PCC,
water proofing treatment, laying of basement raft and beams including filling of earth/

SHEET 6 OF 15
AND BACKFILLING
sand under the basement floor. The water table shall not be allowed to rise above
base of raft level until completion of outer retaining walls including water proofing of
vertical surface of walls and back filling along the walls upto ground level and until
the structure attains such height to counter balance the uplift pressure. The
CONTRACTOR should inspect the site and make his own assessment about sub-
soil water level likely to be encountered at the time of execution and quote his rates
accordingly. Rate of all items are inclusive of pumping out or bailing out water, if
required. Nothing extra on this account whatsoever shall be paid to him. Only when
dewatering is performed by well point dewatering as agreed and approved by
Engineer, the work shall be considered extra and be treated as additional item to be
settled commercially. The CONTRACTOR shall obtain the ENGINEER’s approval
on the sequence of construction.
The CONTRACTOR shall take all necessary measures for the safety of traffic during
construction and provide, erect and maintain such barricades including signs,
markings, flags, lights and flagman, as necessary at either end of the excavation/
embankment and at such intermediate points as directed by the ENGINEER for the
proper identification of construction area. He shall be responsible for all damages
and accidents caused due to negligence on his part.
11.0 EXCAVATION IN HARD ROCK
11.1 GENERAL REQUIREMENTS
Unless otherwise stated herein, IS specification “IS: 4081 - Safety Code for Blasting
and related Drilling Operations” shall be followed. After removal of overburden, if
any, excavation shall be continued in rock to such widths, lengths, depths, and
profiles as are shown in the drawings or such other lines and grades as may be
specified by ENGINEER. As far as possible, all blasting shall be completed prior to
commencement of construction. At all stages of excavation, precautions shall be
taken to preserve the rock below and beyond the lines specified for the excavation,
in the soundest possible condition. The quantity and strength of explosives used
shall be such that it will neither damage nor crack the rock outside the limits of
excavation. All precautions, as directed by ENGINEER, shall be taken during the
blasting operations and care shall be taken that no damage is caused to adjoining
buildings or structures due to blasting operations. In case of damage to permanent
or temporary structures, CONTRACTOR shall repair the same to the satisfaction of
ENGINEER at his cost. As excavation approaches its final lines and levels, the depth
of the charge holes and amount of explosives used shall be progressively and
suitably reduced.
Specific permission of ENGINEER will have to be taken by CONTRACTOR for
blasting rock and he shall also obtain a valid Blasting License from the authorities
concerned. If permission for blasting is refused by ENGINEER, the rock shall be
removed by wedging, pick, barring, heating and quenching or other approved
means. All loose or loosened rock in the sides shall be removed by barring, wedging,
etc. The unit rates for excavation in hard rock shall include the cost of all these
operations.

SHEET 7 OF 15
AND BACKFILLING
CONTRACTOR shall obtain necessary license for storage of explosives, fuses and
detonators issued to him from OWNER’s stores or from supplier arranged by him,
from the authorities dealing with explosives. The fees, if any, required for obtaining
such license, shall be borne by CONTRACTOR. CONTRACTOR shall have to make
necessary storage facilities for the explosives, etc. as per rules of local, State and
Central Government authorities and statutory bodies/ regulations. Explosives shall
be kept dry and shall neither be exposed to direct rays of sun nor be stored in the
vicinity of fire, stoves, steam pipes or heated metal, etc. No explosives shall be
brought near the work in excess of the quantity actually required for a particular
amount of firing to be done; and the surplus left after filling the holes shall be
removed to the magazine. The magazine shall be built, as far as possible, from the
area to be blasted. ENGINEER’s prior approval shall be taken for the location
proposed for the magazine.
In no case shall blasting be allowed closer than 30 metres from any structure or at
locations where concrete has just been placed. In the latter case, the concrete must
be at least 7 days old.
11.2 SPECIFIC REQUIREMENTS
For blasting operations, the following points shall be observed.
CONTRACTOR shall employ a competent and experienced supervisor and licensed
blaster in-charge of each set of operation. These persons shall be held personally
responsible to ensure that all safety regulations are carried out.
Before any blasting is carried out, CONTRACTOR shall intimate ENGINEER and
obtain his approval in writing for resorting to such operations. He shall intimate the
hours of firing charges, the nature of explosive to be used and the precautions taken
for ensuring safety.
CONTRACTOR shall ensure that all workmen and the personnel at site are excluded
from an area within 200 m radius from the firing point, at least 5 minutes before firing
time by sounding warning whistle. The area shall also be given a warning by
sounding a distinguishing whistle.
The blasting of rock near any existing buildings, equipment or any other property
shall be done under cover and CONTRACTOR has to make all such necessary
muffling arrangements. Covering may preferably be done with small charges only
and where directed by ENGINEER, a trench shall have to be cut by chiselling prior
to the blasting operation, separating the area under blasting from the existing
structures.
The firing shall be supervised by a Supervisor and not more than 6 (six) holes at a
time shall be set off successively. If the blasts do not tally with the number fired, the
misfired holes shall be carefully located after half an hour and when located, shall
be exploded by drilling a fresh hole along the misfired hole (but not nearer than 600
mm from it) and by exploding a new charge.
A wooden tamping rod with a flat end shall be used to push cartridges home and
metal rod or hammer shall not be permitted. The charges shall be placed firmly into

SHEET 8 OF 15
AND BACKFILLING
place and not rammed or pounded. After a hole is filled to the required depth, the
balance of the hole shall be filled with stemming which may consist of sand or stone
dust or similar inert material.
CONTRACTOR shall preferably detonate the explosives electrically.
The explosives shall be exploded by means of a primer, which shall be fired by
detonating a Fuse Instantaneous Detonator (FID) or other approved cables. The
detonators with FID shall be connected by special nippers.
In dry weather and normal dry excavation, ordinary low explosive gunpowder may
be used. In damp rock, high explosive like gelatine with detonator and fuse wire may
be used. Underwater or for excavation in rock with substantial accumulated seepage
electric detonation shall be used.
Holes for charging explosives shall be drilled with pneumatic drills, the drilling pattern
being so planned that rock pieces after blasting will be suitable for handling without
secondary blasting.
When excavation has almost reached the desired level, hand trimming shall have to
be done for dressing the surface to the desired level. Any rock excavation beyond
an over-break limit of 75 mm shall be filled up as instructed by ENGINEER, with
concrete of strength not less than M10. The cost of filling such excess depth shall
be borne by CONTRACTOR and the excavation carried out beyond the limit
specified above will not be paid for. Stopping in rock excavation shall be done by
hand trimming.
CONTRACTOR shall be responsible for any accident to workmen, public or
OWNER’s property due to blasting operations. CONTRACTOR shall also be
responsible for strict observance of rules, laid by Inspector of explosives, or any
other Authority duly constituted under the State and/ or Union Government.
12.0 FILL, BACK FILLING AND SITE GRADING
12.1 GENERAL
All fill material will be subject to the ENGINEER's approval. If any material is rejected
by the ENGINEER, the CONTRACTOR shall remove the same forthwith from the
site at no extra cost to the OWNER. Surplus fill material shall be deposited/ disposed
of as directed by the ENGINEER after the fill work is completed.
No earthfill shall commence until surface water discharges and streams have been
properly intercepted or otherwise dealt with as directed by the ENGINEER.
In case of terrace grading, proper slope protection as specified in the drawing or as
approved by the ENGINEER to be ensured at the places of grade level change.
12.2 MATERIAL
To the extent available, selected surplus soils from excavated materials shall be
used as backfill. Fill material shall be free from clods, salts, sulphates, organic or
other foreign material. All clods of earth shall be broken or removed. Where
excavated material is mostly rock, the boulders shall be broken into pieces not larger

SHEET 9 OF 15
AND BACKFILLING
than 150 mm size, mixed with properly graded fine material consisting of murrum or
earth to fill up the voids and the mixture used for filling.
If any selected fill material is required to be borrowed, the CONTRACTOR shall
make arrangements for bringing such material from outside borrow pits. The material
and source shall be subject to prior approval of the ENGINEER. The approved
borrow pit area shall be cleared of all bushes, roots of trees, plants, rubbish, etc. Top
soil containing salts/ sulphates and other foreign material shall be removed. The
materials so removed shall be burnt or disposed off as directed by the ENGINEER.
The CONTRACTOR shall make necessary access road to the borrow areas and
maintain the same, if such access road does not exist, at his cost.
Filling with excavated earth shall be done in regular horizontal layers each not
exceeding 30 cm in depth. All lumps and clods exceeding 80mm in any direction
shall be broken. Each layer shall be watered and consolidated with steel rammer or
half (½) tonne roller. Where specified, every third and top most layer shall also be
consolidated with power roller of minimum 8 tonnes. Wherever depth of filling
exceeds 1.5 metres, vibratory power roller shall be used to consolidate the filling
unless otherwise directed by ENGINEER. The CONTRACTOR shall make good all
subsidence and shrinkage in earth fillings, embankments, traverses, etc. during
execution and till the completion of work unless otherwise specified. Field density
measurements shall be carried out one in each layer.
Any damage to the existing facilities in the site which is not intended as per Drawing,
nor instructed by the Engineer or Owner but is solely due to improper execution of
filling work, shall be restored and made good by the CONTRACTOR as was before
the excavation work started. The cost of such work shall be borne by
CONTRACTOR.
12.3 FILLING IN PITS AND TRENCHES AROUND FOUNDATIONS OF STRUCTURES,
WALLS, ETC.
As soon as the work in foundations has been accepted and measured, the spaces
around the foundations, structures, pits, trenches, etc. shall be cleared of all debris,
and filled with earth in layers not exceeding 150 mm, each layer being watered,
rammed and properly consolidated, before the succeeding one is laid. Each layer
shall be consolidated to the satisfaction of the ENGINEER. Earth shall be rammed
with approved mechanical compaction machines. Usually no manual compaction
shall be allowed unless the ENGINEER is satisfied that in some cases manual
compaction by tampers cannot be avoided. The final backfill surface shall be
trimmed and levelled to proper profile as directed by the ENGINEER or indicated on
the drawings.
12.4 PLINTH FILLING
Plinth filling shall be carried out with approved material as described herein before
in layers not exceeding compacted thickness of 150mm, watered and compacted
with mechanical compaction machines. The ENGINEER may however permit
manual compaction by hand tampers in case he is satisfied that mechanical

SHEET 10 OF 15
AND BACKFILLING
compaction is not possible. When filling reaches the finished level, the surface shall
be flooded with water, unless otherwise directed, for at least 24 hours, allowed to
dry and then again compacted as specified above to avoid settlements at a later
stage. The finished level of the filling shall be trimmed to the level/ slope specified.
Where specified in the schedule of works, compaction of the plinth fill shall be carried
out by means of 12 tonne rollers smooth wheeled, sheep-foot or wobbly wheeled
rollers. In case of compaction of granular material such as sands and gravel,
vibratory rollers shall be used. A smaller weight roller may be used only if permitted
by the ENGINEER. As rolling proceeds water sprinkling shall be done to assist
consolidation. Water shall not be sprinkled in case of sandy fill.
The thickness of each unconsolidated fill layer can in this case be upto a maximum
of 200 mm. The ENGINEER will determine the thickness of the layers in which fill
has to be consolidated depending on the fill material and equipment used.
Rolling shall commence from the outer edge and progress towards the centre and
continue until compaction is to the satisfaction of the ENGINEER, but in no case less
than 10 passes of the roller will be accepted for each layer.
The compacted surface shall be properly shaped, trimmed and consolidated to an
even and uniform gradient. All soft spots shall be excavated and filled and
consolidated.
At some locations/ areas it may not be possible to use rollers because of space
restrictions, etc. The CONTRACTOR shall then be permitted to use pneumatic
tampers, rammers, etc. and he shall ensure proper compaction.
12.5 SAND FILLING IN PLINTH AND OTHER PLACES
At places backfilling shall be carried out with local sand if directed by the ENGINEER.
The sand used shall be clean, medium grained and free from impurities. The filled-
in-sand shall be kept flooded with water for 24 hours to ensure maximum
consolidation. Any temporary work required to contain sand under flooded condition
shall be to the CONTRACTOR's account. The surface of the consolidated sand shall
be dressed to required level or slope. Construction of floors or other structures on
sand fill shall not be started until the ENGINEER has inspected and approved the
fill.
12.6 FILLING IN TRENCHES
Filling in trenches for pipes and drains shall be commenced as soon as the joints of
pipes and drains have been tested and passed. The backfilling material shall be
properly consolidated by watering and ramming, taking due care that no damage is
caused to the pipes.
Where the trenches are excavated in soil, the filling from the bottom of the trench to
the level of the centre line of the pipe shall be done by hand compaction with selected
approved earth in layers not exceeding 80mm; backfilling above the level of the
centre line of the pipe shall be done with selected earth by hand compaction or other
approved means in layers not exceeding 150mm.

SHEET 11 OF 15
AND BACKFILLING
In case of excavation of trenches in rock, the filling upto a level 300mm above the
top of the pipe shall be done with fine materials, such as earth, murrum, etc. The
filling upto the level of the centre line of the pipe shall be done by hand compaction
in layers not exceeding 80mm whereas the filling above the centre line of the pipe
shall be done by hand compaction or approved means in layers not exceeding
150mm. The filling from a level 300mm above the top of the pipe to the top of the
trench shall be done by hand or other approved mechanical methods with broken
rock filling of size not exceeding 150mm mixed with fine material as available to fill
up the voids.
Filling of the trenches shall be carried simultaneously on both sides of the pipe to
avoid unequal pressure on the pipe.
13.0 GENERAL SITE GRADING
Site grading shall be carried out as indicated in the drawings and as directed by the
ENGINEER. Excavation shall be carried out as specified in the specification. Filling
and compaction shall be carried out as specified under clause 12.0 and elsewhere
unless otherwise indicated below.
If no compaction is called for, the fill may be deposited to the full height in one
operation and levelled. If the fill has to be compacted, it shall be placed in layers not
exceeding 225 mm and levelled uniformly and compacted as indicated in clause 12.0
before the next layer is deposited.
To ensure that the fill has been compacted as specified, field and laboratory tests
shall be carried out by the CONTRACTOR at his cost.
Field compaction test shall be carried out at each of the different stages of filling and
at frequency of one test in each layer per 2000 sqm area and also after the fill to the
entire height has been completed. This shall hold good for embankments as well.
The CONTRACTOR shall protect the earthfill from being washed away by rain or
damaged in any other way. Should any slip occur, the CONTRACTOR shall remove
the affected material and make good the slip at his cost.
The fill shall be carried out to such dimensions and levels as indicated in the
drawings after the stipulated compaction. The fill will be considered as incomplete if
the desired compaction has not been achieved.
If specifically permitted by the ENGINEER, compaction can be achieved by allowing
loaded trucks conveying fill or other material or chain tracked vehicles to ply over the
fill area. Even if such a method is permitted, it will be for the CONTRACTOR to
demonstrate that the desired/ specified compaction has been achieved. In order that
the fill may be reasonably uniform throughout, the material should be dumped in
place in approximately uniform layers. Traffic over the fill shall then be so routed to
compact the area uniformly throughout.
If so specified, the rock as obtained from excavation may be used for filling and
levelling to required grades without further breaking. In such an event, filling shall be
done in layers not exceeding 50 cm approximately. After rock filling to the
approximate level indicated above, has been carried out, the void in the rocks shall

SHEET 12 OF 15
AND BACKFILLING
be filled with finer materials such as earth, broken stone, etc. and the area to be
flooded so that the finer materials fill up the voids. Care shall be taken to ensure that
the finer fill material does not get washed out. Over the layer so filled, a 100 mm
thick mixed layer of broken material and earth shall be laid, and consolidation carried
out by a 12 tonne roller. No less than twelve passes of the roller shall be accepted
before subsequent similar operations are taken up.
14.0 SITE FILLING
14.1 FILL MATERIAL
14.1.1 General
All fill material whether such material is brought from outside borrow areas or from
excavation from within the site, will be subject to the ENGINEER’s written approval.
Notwithstanding any approval given to the fill material of borrow areas from which fill
material is proposed to be brought, the ENGINEER/ OWNER reserves the right to
reject such material, which in his opinion either does not meet the specification
requirements or is unsuitable for the purpose for which it is intended.
14.1.2 Borrow Areas
It shall be CONTRACTOR’s responsibility to locate suitable borrow areas for
borrowing fill material. Such area will be inspected by the ENGINEER and approved
before the CONTRACTOR makes arrangements to borrow the fill material. The top
soil which may contain vegetation, rubbish, slush, etc. shall not be used. If
demanded by the ENGINEER, the CONTRACTOR shall arrange to have trial pits of
specified dimensions and numbers dug at locations specified, for the ENGINEER to
examine the nature and type of material likely to be obtained from the borrow area.
14.1.3 Lead, Lift and Transportation
Unless separately provided for, all lead, lift and transportation required for bringing
in the fill material from borrow areas or from excavation from within the site shall be
included in the CONTRACTOR’s quoted unit rates.
14.1.4 Quality
The borrowed soil shall be generally granular, and non-cohesive. It shall consist of
sand, silty sand, murrum, ordinary soil, gravel and shingle. Dredged material shall
also be free from sulphates, salts, organic, foreign and other harmful or objectionable
materials. Any material rejected by the ENGINEER shall be removed from the site
immediately.
14.2 ACCESS ROADS
Roads, whether of temporary or other nature, required to be constructed for access
and for movement of men, materials, equipment, transport vehicles, vehicles
carrying fill material, etc. to or over borrow areas and/ or to or over areas on which
fill has to be deposited shall be constructed by the CONTRACTOR at his cost. Such
costs shall be deemed to have been included in the unit rates quoted by the

SHEET 13 OF 15
AND BACKFILLING
CONTRACTOR. Such access roads shall be maintained in good condition during all
seasons to ensure completion of work according to time schedule.
14.3 CLEARING
Site clearing before filling shall be carried out as per clause 5.0 of this specification.
14.4 FILLING
14.4.1 Sand Fill
a) Sandy fill shall be deposited to bring the grade level to desired elevation after
compaction of fill. Sandy fill shall be carried out as per the method indicated
in the drawings.
b) Compaction of sandy fill by flooding the area shall be carried out where so
specified. In this case, CONTRACTOR should ensure that the fill material is
not washed away. This work should be carried out as directed by ENGINEER.
c) Sandy fill shall be compacted, where so specified, by 12 tonne vibratory
rollers. The fill material shall be compacted to the specified density.
d) If the density of fill or use of rollers for compaction is not specified, the
CONTRACTOR shall ensure necessary compaction by the passage of trucks,
carrying the fill material over the deposited fill in such a way that the entire fill
area is covered. This will reasonably compact the sand fill and will be accepted
by the ENGINEER. However, the CONTRACTOR shall ensure that every
layer is thus compacted before the succeeding layers are deposited. Each
layer shall not exceed 200 mm in thickness.
14.4.2 Soil Fill
a) Approved soil fill consisting of ordinary soil, murrum, soil containing gravel,
shingle, etc. shall be deposited in layers not exceeding 200 mm.
CONTRACTOR should ensure that all clods of earth are broken down to a
size not larger than 100 mm.
b) Where density of fill or use of rollers is not specified, the fill shall be carried
out as specified in this specification.
c) Where the fill material has to be compacted by use of rollers procedure as
specified in clause 12.4of this specification shall be followed.
d) Where specified, the required density of fill shall be obtained by proper
compaction.
15.0 FILL DENSITY
The compaction, where so called for, in the Schedule of Quantities/ Items shall
comply with the specified (Standard Proctor/ Modified Proctor) density at moisture
content differing not more than 2 percent from the optimum moisture content. The
CONTRACTOR shall demonstrate adequately at his cost, by field and laboratory
tests that the specified density has been obtained.
16.0 PROPERTIES OF FILLING MATERIAL
The soil selected for filling purpose shall comply with the following requirements:
a) Soil shall be free from swelling properties. Preferably, soil having free swelling
index less than 50 shall be used. However, soil having free swelling index up

SHEET 14 OF 15
AND BACKFILLING
to 100 may be used after carrying out necessary soil improvement and
approval by ENGINEER. Liquid Limit and Plasticity Index shall be as per Table
8 of IS: 1498 for low degree of expansion.
b) It shall be possible to compact the soil upto 97% of Proctor Density or Modified
Proctor Density as per the project requirement. Broad guidelines for selection
of various types of soil groups and their requirements for compaction are
indicated in Table 8 of IS: 1498.
c) Soil shall be free from chemical contamination. It shall have pH value,
sulphate and chloride content within the permissible values specified in IS:
456.
17.0 LEAD
Lead for deposition/ disposal of excavated material, shall be as specified in the
respective item of work. For the purpose of measurement of lead, the area to be
excavated or filled or area on which excavated material is to be deposited/ disposed
of shall be divided into suitable blocks and for each of the blocks, the distance
between centre lines shall be taken as the lead, which shall be measured by the
shortest straight line route on the plan and not the actual route taken by the
CONTRACTOR. No extra compensation shall be admissible on the grounds that the
lead including that for borrowed material had to be transported over marshy or
'kutcha' land/ route.
18.0 MEASUREMENT AND PAYMENT
All excavation shall be measured net. Dimensions for purpose of payment shall be
reckoned on the horizontal area of the excavation at the base for foundations of the
walls, columns, footings, tanks, rafts or other foundations/ structures to be built,
multiplied by the mean depth from the surface of the ground in accordance with the
foundation drawings. Excavation in side slopes will not be paid for. The
CONTRACTOR may make such allowance in his rates to provide for excavation in
side slopes keeping in mind the nature of the soil and safety or excavation. However,
if the concreting is proposed against the excavated sides, no such over excavation
will be permitted. In such cases, over excavation shall be made good by the
CONTRACTOR with concrete of the same class as in the foundations at his cost.
Dewatering by ordinary methods not requiring well point shall be included in the
quoted rates for excavation.
Unless otherwise specified, the unit rates quoted for excavation in different types of
material shall also account for a basic lead of 100 metres for disposal as specified
or directed. Only leads beyond the basic lead of 100 metres will be considered as
extra lead and paid for at the rates quoted in the schedules.
Backfilling, as per specification, the sides of foundations, columns, structures, walls,
tanks, rafts, trenches, etc. with excavated material will not be paid for separately. It
shall be clearly understood that the rate quoted for excavation including backfilling
shall include stacking of excavated material as directed, excavation/ packing of
selected stacked material, conveying it to the place of final backfill, compaction, etc.

SHEET 15 OF 15
AND BACKFILLING
as specified. As a rule material to be backfilled shall be stacked temporarily within

the basic lead of 100 metres unless otherwise directed by the ENGINEER. If the
ENGINEER directs/ permits a lead of over 100 metres for such material, the
conveyance of the material for the extra distance over the basic lead of 100 metres
for backfilling will be paid for.
Payment for fill inside trenches, plinth or similar filling with selected excavated
material will be made for only compacted soil volume as specified/ directed. Cost of
all other operations shall be deemed to have been covered in the rate quoted for
filling. Payment for this work will be made based on measurement of plinth/ trench
dimensions filled. The plinth ground levels shall be surveyed before for this purpose.
If no compaction is specified/ desired, such filling will not be separately paid for. In
such an event the fill shall be levelled/ finished to the profile as directed at no extra
cost.
Backfilling, plinth filling, etc. with borrowed earth will be paid for at rates quoted. The
quoted rate shall include all operations such as clearing, excavation, lead and
transport, fill, compaction, etc. as specified. Actual quantity of consolidated filling
shall be measured and paid for in cubic metres. The lead, lift, etc. shall be as
indicated in the Schedule of Quantities.
Actual quantity of consolidated sand filling shall be measured and paid in cubic
metres.
Volume of rock excavated shall be calculated on the basis of length, breadth and
depth of excavation dimension as per the foundation drawings.
No payment will be made for excavations/ over-break beyond payment line specified.
Where such measurement is not possible as in the case of strata intermixed with
soil, excavated rock shall be properly stacked as directed by ENGINEER and the
volume of rock calculated on the basis of stack measurements after making
appropriate allowance for voids. The allowance to be made for voids shall be decided
by ENGINEER and this will not be a subject matter of dispute or appeal.
Measurement for Site Filling will be made on the basis of this specification.
END

TCE.M4-418-03
SPECIFICATION FOR DEWATERING SHEET 1 OF 1
1.0 SCOPE
This specification covers the general requirements of dewatering excavations in
general.
2.0 DEWATERING
All excavations shall be kept free of water. Grading and surface water drainage
scheme in the vicinity of excavation shall be properly closed to prevent surface water
from draining into excavated areas. CONTRACTOR shall remove by pumping or other
means approved by ENGINEER any water inclusive of rain water and subsoil water
accumulated in excavation and keep all excavations dewatered until the foundation
work is completed and backfilled. Sumps made for dewatering must be kept clear of
the excavation/ trench areas required for further work of foundation construction.
Method of pumping shall be approved by ENGINEER; but in any case, the pumping
arrangement shall be such that there shall be no movement of subsoil or blowing in or
excavation wall collapse due to differential head of water during pumping. Pumping
arrangements shall be adequate to ensure no delays in construction.
The CONTRACTOR shall take adequate measures for bailing and/ or pumping out
water from excavations and construct diversion channels, bunds, sumps, coffer dams,
etc. as may be required. Pumping shall be done directly from the foundation trenches
or from a sump outside the excavation in such a manner as to preclude the possibility
of movement of water through any fresh concrete or masonry and washing away parts
of concrete or mortar. During laying of concrete or masonry and for a period of at least
24 hours thereafter, pumping shall be done to ensure that the surface below the
concrete remains dry.
Capacity and number of pumps, location at which the pumps are to be installed,
pumping hours, etc. shall be reviewed by the CONTRACTOR from time to time. The
ENGINEER may direct the CONTRACTOR to make changes in his scheme if the
adopted scheme fails to achieve the desired results.
Pumping shall be done in such a way as not to cause damage to the work or adjoining
property by subsidence, etc. Disposal of water shall not cause inconvenience or
nuisance in the area or cause damage to the property and structures nearby or shall
not be a cause for environmental pollution of natural water bodies.
When there is a continuous inflow of water and quantum of water to be handled is
considered in the opinion of ENGINEER as large, well point system - Single stage or
multi stage, shall be adopted. CONTRACTOR shall submit to ENGINEER his scheme
of well point system including the stages, the spacing, number and diameter of well
points, headers, etc. and the numbers, capacity and location of pumps of approvals.
Normal dewatering using bailing arrangement, submersible pumps shall be included
in the item rate for excavation. Special dewatering system using well point system shall
be considered as separate item.
In case well point dewatering is required, the Indian Standard IS 9759: 1981
(Reaffirmed 2016) - Guidelines for De-Watering During Construction shall be used for
design of the dewatering system.
FILENAME: M4-418-03-REV-03.DOCX
disclose this information to any person outside the recipient’s organisation; except that there is no obligation to maintain the confidentiality of any information which was known to the recipient prior to receipt of
ISSUE
such information from Tata Consulting Engineers Limited, or becomes publicly known through no fault of recipient, or Tata Consulting Engineers Limited, or is received without obligation of confidentiality from
a third party owing no obligation of confidentiality to Tata Consulting Engineers Limited. All information given under this version over rides all and any kind of offers, assumptions, deliverables and contracts
R3
FILE NAME: M4-418-03-Rev-03.docx TCE FORM NO. 329 R7

TCE.M4-418-03
SPECIFICATION FOR DEWATERING SHEET 2 OF 2
3.0 MEASUREMENT
Normal dewatering using bailing arrangement, submersible pumps shall be included
in the item rate for excavation. Special dewatering system using well point system shall
be considered as separate item. If such special items are not included in the schedule
of quantities but required to be operated, it shall be treated as an extra item and
separate rate shall be obtained from contractor and agreed upon between Owner and
Contractor.
END
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TCE.M4-403-01
SPECIFICATION FOR REINFORCED CONCRETE AND
SHEET 1 OF 40
ALLIED WORKS
1.0 SCOPE
1.1 This Specification covers the general requirements for ready mixed concrete and
for concrete using on-site production facilities including requirements with regard
to the quality, handling, storage of ingredients, proportioning, batching, mixing,
transporting, placing, curing, protecting, repairing, finishing and testing of concrete;
formwork; requirements with regard to the quality, storage, bending and fixing of
reinforcement; grouting as well as mode of measurement and payment for
completed works.
1.2 It shall be very clearly understood that the specifications given herein are brief and
do not cover minute details. However, all works shall have to be carried out in
accordance with the relevant standards and codes of practices or in their absence
in accordance with the best accepted current Engineering practices or as directed
by ENGINEER from time to time. The decision of ENGINEER about the
specification to be adopted and their interpretation and the mode of execution of
work shall be final and binding on CONTRACTOR and no claim whatsoever will be
entertained on this account.
2.0 APPLICABLE CODES AND SPECIFICATIONS
2.1 The pertinent clauses of the following Indian Codes, Standards and Specification
shall apply to the material and workmanship covered by this specification. In the
event of the conflict of certain requirements between this specification and the
codes referred herein, this specification shall govern.
2.2 The codes and standards mentioned herein shall be latest as on the day of award
of contract of the works unless otherwise specified. Contractor shall be responsible
to inform to the Consultant/ Owner in case of any revisions/re-affirm/amendment in
the relevant codes and standards after the date of award of contract within 30 days
of the issue of such revision/re-affirm/amendment of the code/ standard.
Consultant/ Owner may approve use of the earlier code/ standard if the revisions
do not materially affect the statutory requirements of the project or does not impact
safety practices. Any cost impact arising out of such revisions shall be mutually
agreed.
2.3 It is not the intent to specify herein all the codes and standards required for the
satisfactory completion of work. The list of codes and standards indicates certain
primary codes and standards and not all the codes required for the work under the
contract. It is understood that all the pertinent codes and standards shall form the
part of this specification whether explicitly indicated or not. Indian Standards shall
be supplemented by International Standards for clarity and coverage wherever felt
so.
FILE NAME:M4.403-01-Rev.R10
This document contains confidential information for use only by the “Client”; for the Project under consideration, which is provided for the sole purpose of permitting the recipient to evaluate the information submitted
herewith. In consideration of receipt of this document; unless agreed to in contrary in the Contract; the recipient agrees to maintain such information in confidence and to not reproduce or otherwise disclose this
ISSUE
information to any person outside the recipient’s organisation; except that there is no obligation to maintain the confidentiality of any information which was known to the recipient prior to receipt of such information
from Tata Consulting Engineers Limited, or becomes publicly known through no fault of recipient, or Tata Consulting Engineers Limited, or is received without obligation of confidentiality from a third party owing no
R11
obligation of confidentiality to Tata Consulting Engineers Limited. All information given under this version over rides all and any kind of offers, assumptions, deliverables and contracts submitted verbally (and
subsequently communicated in writing) or in writing or otherwise given under all previous version/s.
FILE NAME: M4-403-01-Rev.R11.docx

SPEC. NO.
TCE.M4-403-01 SPECIFICATION FOR REINFORCED CONCRETE AND
SHEET 2 OF 40
ALLIED WORKS
2.4 MATERIALS
IS 455:2015 Specification for Portland Slag Cement.
IS 1489: PART 1: Portland pozzolana cement - specification part 1 fly ash
2015 based
IS 1489: PART 2: Portland pozzolana cement - specification part 2 calcined
2015 clay based (fourth revision)
IS 8112:2013 Ordinary Portland Cement, 43 Grade
IS 12330: 1988
Specification for Sulphate Resisting Portland Cement
(Reaffirmed 2019)
Coarse and fine aggregate for concrete - specification (third
IS 383: 2016
revision)
Specification for Mild Steel and Medium Tensile Steel Bars
IS 432: 1982
and Hand Drawn Steel Wire for Concrete Reinforcement –
(Reaffirmed 2015)
Part 1 and 2
IS 1786: 2008 High strength deformed steel bars and wires for concrete
(Reaffirmed 2018) reinforcement - specification
IS 1566:1982 Specification for hard-drawn steel wire fabric for concrete
Reaffirmed 2015 reinforcement
IS 9103:1999
Concrete admixtures - specification
Reaffirmed 2018
IS 2645:2003 Integral waterproofing compounds for cement mortar and
Reaffirmed 2017 concrete - specification
IS 4990:2011
Plywood for concrete shuttering work - specification
Reaffirmed 2017
IS 4926:2003
Ready-mixed concrete - code of practice
Reaffirmed 2017
IS 12269: 2013 Ordinary Portland Cement, 53 Grade
IS 8041:1990
Specification for rapid hardening cement.
Reaffirmed 2019
IS 12600: 1989
–Specification for Low Heat Portland Cement
(Reaffirmed 2019)
IS 6909: 1990
Specification for super-sulphated cement
(reaffirmed 2016)
IS 12089:1987 Specification for granulated slag for manufacture of portland
Reaffirmed 2018 slag cement
ISSUE
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FILE NAME: M4-403-01-Rev.R11.docx TCE FORM NO. 329 R7

SPEC. NO.
SHEET 3 OF 40
ALLIED WORKS
2.5 MATERIAL TESTING
IS 4031 (Part 1 to Methods of physical tests for hydraulic cement
15): Reaffirmed
2019
IS 4032:1985 Method of chemical analysis of hydraulic cement.
Reaffirmed 2019
IS 650:1991 Specification for standard sand for testing of cement.
Reaffirmed 2013
IS 2430:1986 Methods for sampling of aggregates for concrete.
Reaffirmed 2014
DIN EN
12620:2015-07- Aggregates for concrete (Refer Note).
DRAFT
IS 2386:1963 Methods of test for aggregates for concrete (Parts 1 to 8)
Reaffirmed 2016
IS 3025 (Part 1 to Methods of sampling and test (physical and chemical) for
51): Reaffirmed water and wastewater
Latest Year
Is 6925: 1973 METHODS OF TEST FOR DETERMINATION OF WATER-
(reaffirmed 2018) SOLUBLE CHLORIDES IN CONCRETE ADMIXTURES
NOTE: These tests are optional and shall be carried out by the contractor at his
cost, if directed by ENGINEER.
2.6 MATERIAL STORAGE
IS 4082:1996 Recommendations on stacking and storage of
Reaffirmed 2018 construction materials and components at site.
2.7 CONCRETE MIX DESIGN
IS 10262:2019 Concrete mix proportioning-guidelines
2.8 CONCRETE TESTING
IS 1199:1959
Method of sampling and analysis of concrete.
Reaffirmed 2018
IS 516:1959
Method of test for strength of concrete.
Reaffirmed 2018
IS 9013:1978 Method of making, curing and determining compressive
Reaffirmed 2018 strength of accelerated cured concrete test specimens.
IS 8142:1976 Method of test for determining setting time of concrete by
Reaffirmed 2016 penetration resistance.
IS 9284:1979
Method of test for abrasion resistance of concrete.
Reaffirmed 2016
IS 2770
Methods of testing bond in reinforced concrete: Part 1
(Part 1):1967
Pull-out test
Reaffirmed 2017
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SPEC. NO.
SHEET 4 OF 40
ALLIED WORKS
2.9 EQUIPMENT
IS 4925:2004 Specification for concrete batching and mixing plant.
Reaffirmed 2015
IS 7251:1974 Specification for concrete finishers.
Reaffirmed 2017
IS 2750:1964 Specifications for steel scaffoldings.
Reaffirmed 2016
2.10 CODES OF PRACTICE
IS: 456:2000
Plain and reinforced concrete - code of practice.
Reaffirmed 2016
Code of practice for general construction of plain and
IS: 457:1957
reinforced concrete for dams and other massive
Reaffirmed 2019
structures.
IS 3370
Concrete structures for storage of liquids - code of practice -
(Part 1):2009
part 1 : general requirements
Reaffirmed 2019
IS 3370
Concrete structures for storage of liquids - code of practice -
(Part 2):2009
part 2 : reinforced concrete structures
Reaffirmed 2019
IS 3370
Code of practice for concrete structures for the storage of
(Part 3):1967
liquids: part 3 prestressed concrete structures
Reaffirmed 2019
IS 3370
Code of practice for concrete structures for the storage of
(Part 4):1967
liquids: part 4 design tables
Reaffirmed 2019
IS 3935:1966
Code of practice for composite construction.
Reaffirmed 2017
IS 2204:1962 Code of practice for construction of reinforced concrete
Reaffirmed 2015 shell roof.
IS 2210:1988 Criteria for the design of reinforced concrete shell
Reaffirmed 2017 structures and folded plates.
IS 2502:1963 Code of practice for bending and fixing of bars for concrete
Reaffirmed 2018 reinforcement.
IS 5525:1969 Recommendation for detailing of reinforcement in
Reaffirmed 2018 reinforced concrete works.
IS 2751:1979 Code of practice for welding of mild steel plain and
Reaffirmed 2019 deformed bars used for reinforced concrete construction.
Welding of high strength steel bars for reinforced concrete
IS 9417:2018
construction-recommendations
IS 3558:1983 Code of practice for use of immersion vibrators for
Reaffirmed 2018 consolidating concrete.
IS 3414:1968 Code of practice for design and installation of joints in
Reaffirmed 2015 buildings.
ISSUE
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SPEC. NO.
SHEET 5 OF 40
ALLIED WORKS
IS 4326:2013 Earthquake resistant design and construction of buildings -

Reaffirmed 2018 code of practice
IS 4014
Code of practice for steel tubular scaffolding Part 1
(Part 1):1967
Definitions and materials
Reaffirmed 2016
IS 4014 Code of practice for steel tubular scaffolding: Part 2 Safety
(Part 2):2013 regulations for scaffolding (first revision)
IS 2571:1970
Code of practice for laying in situ cement concrete flooring
Reaffirmed 2017
IS 7861
Code of practice for extreme weather concreting: Part
(Part 1):1975
1Recommended practice for hot weather concreting
Reaffirmed 2016
IS 7861
Code of practice for extreme weather concreting: Part
(Part 2):1981
2Recommended practice for cold weather concreting
Reaffirmed 2016
IS 3812 (Part 1): Pulverized fuel ash – Part 1 – For use as pozzolana in
2013 cement, cement mortar and concrete
IS 15388: 2003 Specification for Silica Fume
2.11 CONSTRUCTION SAFETY

IS 3696 Safety code of scaffolds and ladders: Part 1 Scaffolds (first
(Part 1):1987 revision)
Reaffirmed 2017
IS 3696 Safety code of scaffolds and ladders: Part 2 Ladders (first
(Part 2):1991 revision)
Reaffirmed 2017
IS 7969:1975 Safety code for handling and storage of building materials.
Reaffirmed 2017
IS 8989:1978 Safety code for erection of concrete framed structures.
Reaffirmed 2015
2.12 MEASUREMENT
IS 1200 Method of measurement of building and Engineering

(Part 2):1974 works (Part 2 and 5) Methods of measurement of
building and civil engineering works: Part 2 Concrete
Reaffirmed 2012
works (third revision)
IS 1200 Methods of measurement of building and civil
(Part 5):2013 engineering works: part 5 Form work (fourth revision)
3.0 GENERAL
3.1 ENGINEER shall always have the right to inspect all operations including the
sources of materials, procurement, layout and storage of materials, the
concrete batching and mixing equipment, and the quality control system. Such ISSUE
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starting of concrete work. This shall, however, not relieve CONTRACTOR of
any of his responsibilities. All materials, which do not conform to this
specification, shall be rejected.
3.2 Materials should be selected so that they can satisfy the design requirements
of strength, serviceability, safety, durability and finish with due regards to the
functional requirements and the environmental conditions to which the structure
will be subjected. Materials complying with codes/ standards shall only be used.
Other materials may be used after approval of the ENGINEER and after
establishing their performance suitability based on previous data, experience
or tests.
4.0 MATERIALS
4.1 CEMENT
4.1.1 Unless otherwise specified or called for by ENGINEER/ OWNER, cement shall
be Ordinary Portland Cement conforming to IS: 269, IS: 8112 or IS: 12269.
4.1.2 The Portland Pozzolana Cement shall conform to IS: 1489 & Portland Slag
Cement conforming to IS: 455 shall be used as directed by ENGINEER.
4.1.3 Sulphate Resisting Portland Cement conforming to IS: 12330 may be used for
mass concrete construction and generally complying with IS: 12330, but with
Tricalcium Aluminate (C3A) content not more than 5% by mass (as
manufactured by an approved manufacturer) may be used for reinforced
concrete construction.
4.1.4 Only one type of cement shall be used in any one mix unless specifically
approved by ENGINEER. The source of supply, type or brand of cement within
the same structure or portion thereof shall not be changed without prior
approval from ENGINEER.
4.1.5 Cement, which is not used within 90 days from its date of manufacture, shall
be tested at a laboratory approved by ENGINEER and until the results of such
tests are found satisfactory, it shall not be used in any work.
4.1.6 Fly Ash Blended Cements conforming to IS: 1489 (Part I) may be used in RCC
structures as per the guidelines given below:
4.1.7.1 General
(a) IS: 456 - Code of Practice for Plain and Reinforced Concrete shall be
followed about Concrete Mix Proportion and its production as under:
i. The concrete mix design shall be done as “Design Mix Concrete”
as prescribed in clause 9 of IS: 456.
ii. Concrete shall be manufactured in accordance with clause 10 of
IS 456 covering Quality Assurance measures.
(b) Minimum M25 grade of concrete shall be used in all structural elements
made with RCC both in load bearing and framed structure.
(c) The mechanical properties such as modulus of elasticity, tensile
strength, creep and shrinkage of fly ash mixed concrete or concrete
using fly ash blended cements (PPCs) are not likely to be significantly
different and their values are to be taken same as those used for
concrete made with OPC.
If necessitated due to low water/ binder ratio, required workability shall
be achieved by use of chloride free chemical admixtures conforming to
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plasticisers with each set OPC, fly ash and/ or PPC received from
different sources shall be ensured by trials.
(d) In cases, where structural concrete is exposed to excessive magnesium
sulphate, fly ash substitution/ content shall be limited to 18% by weight.
Special type of cement with low C3A content may also be alternatively
used. Durability criteria like minimum binder content and maximum
water/ binder ratio also need to be given due consideration in such
environment.
(e) Wet curing period shall be enhanced to a minimum of 10 days or its
equivalent. In hot and arid regions, the minimum curing period shall be
14 days or its equivalent.
4.1.7 Use of Fly Ash Admixed Cement Concrete (FACC) in RCC Structures
There shall be no bar on use of FACC in RCC structures subject to following
additional conditions.
(a) Fly ash shall have its chemical characteristics and physical requirements,
etc. conforming to IS: 3812 (Parts I) and shall be duly certified.
(b) To ensure uniform blending of fly ash with cement in conformity with IS:
456, a specific facility needs to be created at site with complete
computerised automated process control to achieve design quality or with
similar facility from Ready Mix Concrete (RMC) plants.
(c) As per IS: 1489 (Part-I) maximum 35% of OPC by mass is permitted to
be substituted with fly ash conforming to IS: 3812 (Part-I).
(d) Separate storage for dry fly ash shall be provided. Storage bins or silos
shall be weather proof and permit a free flow and efficient discharge of fly
ash. The filter or dust control system provided in the bins or silos shall be
of sufficient size to allow delivery of fly ash maintained at specified
pressure to prevent undue emission of fly ash dust, which may interfere
with weighing accuracy.
4.1.8 Use of Silica Fume Admixed Cement Concrete in RCC Structures
Silica fume conforming to IS 15388 may be used to the extent of 5 – 10% of
the cement content as stipulated in IS 456 as a part replacement of cement.
4.1.9 Use of Fly Ash Blended Cements in Cement Concrete (PPCC) in RCC
Structures
(a) Subject to General Guidelines detailed out as above, PPC
manufactured conforming to IS: 1489 (Part-I) shall be treated at par with
OPC for manufacture of Design Mix concrete for structural use in RCC.
(b) Till the time, Bureau of Indian Standards (BIS) makes it mandatory to
print the percentage of fly ash on each bag of cement, the certificate
from the PPC manufacture indicating the same shall be insisted upon
before allowing use of such cements in works.
(c) While using PPC for structural concrete work, no further admixing of fly
ash shall be permitted.
4.2 AGGREGATES
4.2.1 Aggregates shall consist of naturally occurring stones and gravel (crushed or
uncrushed) and sand. They shall be chemically inert, strong, hard, clean,
durable against weathering, of limited porosity, free from dust/ silt/ organic
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slag, crushed over burnt bricks, bloated clay ash, sintered fly ash and tiles shall
not be used.
4.2.2 Aggregates shall be washed and screened before use where necessary or if
directed by the ENGINEER.
4.2.3 Aggregates containing reactive materials shall be used only after tests
conclusively prove that there will be no adverse effect on strength, durability
and finish, including long term effects, on the concrete.
4.2.4 The fineness modulus of sand shall neither be less than 2.2 nor more than 3.2.
If use of sand having fineness modulus more than 3.2 is unavoidable then it
shall be suitable blended with crusher stone dust.
4.2.5 The maximum size of coarse aggregate shall be as stated on the drawings, but
in no case greater than 1/4 of the minimum thickness of the member, provided
that the concrete can be placed without difficulty to surround all reinforcement
thoroughly and fill the corners of the form.
4.2.6 For concrete elements less than 100 mm thick, consideration should be given
to the use of 10 mm nominal maximum size aggregates. Where 10 mm
maximum size aggregate is required, 10 mm single-size grading shall be used.
4.2.7 Plums 160 mm and above of a reasonable size may be used where directed.
Plums shall not constitute more than 20% by volume of concrete unless
specified by ENGINEER.
4.3 WATER
4.3.1 Water used for both mixing and curing shall conform to IS: 456. Potable water
is generally satisfactory. Water containing any excess of acid, alkali, sugar or
salt shall not be used.
4.3.2 The pH value of water shall not be less than 6.
4.3.3 Seawater shall not be used for concrete mixing and curing.
4.4 REINFORCEMENT
4.4.1 Reinforcement bars shall conform to IS: 432 and/ or IS: 1786 and welded wire
fabric to IS: 1566 as shown on the drawing.
4.4.2 All reinforcement shall be clean, free from pitting, oil, grease, paint, loose mill
scales, rust, dirt, dust or any other substance that will destroy or reduce bond.
4.4.3 Special precaution like coating of reinforcement may be provided with the prior
approval of ENGINEER.
4.5 ADMIXTURES AND ADDITIVES
4.5.1 Approval of Admixtures
Admixture from approved manufacturer shall be used in concrete mix along
with aggregates, cement and water without the written instruction or approval
of the ENGINEER in each case. If more than one admixture is proposed for
use in the same concrete mix, their interaction shall be checked by trial mixes
to ensure their compatibility.
The CONTRACTOR shall note that the description of any proposed admixture
by trade or brand name will not be sufficient for the approval of the ENGINEER.
The CONTRACTOR shall submit manufacturer's test certificates and technical
literature of the admixture proposed to be used. If directed by the ENGINEER,
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The ENGINEER will, wherever appropriate, call for trial batches of concrete to
be prepared to demonstrate the effect of the proposed admixtures both on the
fresh concrete and on the hardened concrete before giving his approval. He
may also lay down additional requirements for the control of the use of such
admixtures.
Notwithstanding any previously given approval, the ENGINEER may withdraw
such approval at any time with respect to any mix containing admixtures if, in
his opinion, the performance of the admixture under actual Site conditions is
not completely satisfactory.
4.5.2 Supply and Storage of Admixtures
Accelerating, retarding, water-reducing, super plasticizing and air entraining
admixtures shall conform to IS: 9103, integral cement water proofing admixture
to IS: 2645, any other admixture to BS: 5075, if it is applicable, unless otherwise
specified or agreed. Admixtures shall be stored strictly in accordance with
manufacturers’ recommendations and precautions shall be taken during
delivery and storage to prevent damage to or adulteration of admixtures.
4.5.3 Use of Admixtures
Any admixture used in any concrete mix shall only be used at the rate of dosage
or in the proportions previously approved by the ENGINEER, method of mixing,
etc. all in accordance with the manufacturer’s instructions and within the
manufacturer’s recommended ambient temperature range.
Any batch of concrete, which has received an incorrect dose of an admixture
or which shall show deterioration after placing because of incorrect use of
admixtures, shall be broken out or otherwise replaced at no additional cost to
the OWNER.
The relative density of liquid admixtures shall be checked for each drum
containing the admixture and compared with the stated/ specified value before
acceptance. Liquid admixtures or powder admixtures that are to be used as
solutions shall be dispensed by an appliance fixed to the mixer, which
measures weight, volume or dosing time and is provided with a recorder. This
appliance shall be accurately calibrated, and the calibration and dosage shall
be checked at regular intervals or as directed by the ENGINEER. All such
admixtures shall be dispensed with the mixing water.
All admixture dispensers shall be thoroughly cleaned before commencing each
day’s work and at every interruption to the work.
Where admixtures are to be used in bulk form, these shall be weigh-batched
as is provided in this Specification for the batching of cement.
Powder admixtures to be used in dose form shall only be allowed if premixed
and used as solutions and then only if the premixing procedure has been
previously approved by the ENGINEER.
4.5.4 Corrosion Inhibitor
The use of proprietary corrosion inhibitors, whether specified or not, shall be
subject to the written agreement of the ENGINEER. Their prime function shall
be to form a protective film on the reinforcing steel.
Proprietary corrosion inhibitors shall be added to the concrete in accordance
with the recommendations of the manufacturer. The dosage and rate of
application shall be established by the CONTRACTOR following consultation
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with the admixture manufacturer and shall be confirmed to the ENGINEER in
writing.
4.5.5 Chlorides
Under no circumstances shall calcium chloride or chloride-based admixtures
be used in any concrete mix, grout or mortar. The chloride content of
admixtures shall be independently tested in an approved laboratory for each
batch of admixture before acceptance. Calcium chloride shall not be used for
accelerating set of the cement for any concrete containing reinforcement or
embedded steel parts. When calcium chloride is permitted such as in mass
concrete works, it shall be dissolved in water and added to the mixing water by
an amount not exceeding 1.5% of the weight of the cement in each batch of
concrete. The designed concrete mix shall be corrected accordingly.
4.6 WASTAGE
4.6.1 Wastage allowance for cement and reinforcing steel (supplied by OWNER)
shall be as specified in Instructions to Bidders.
4.7 SAMPLES AND TESTS
4.7.1 All materials used for the works shall be tested before use. The frequency of
such confirmatory tests shall be decided by ENGINEER.
4.7.2 Manufacturer’s test certificate shall be furnished for each batch of cement/
reinforcing steel and when directed by ENGINEER samples shall also be got
tested by the CONTRACTOR in a laboratory approved by ENGINEER at no
extra cost to OWNER. However, where material is supplied by OWNER, all
testing charges shall be borne by OWNER, but transportation and preparation
of material samples for the laboratory shall be done by CONTRACTOR at no
extra cost.
4.7.3 Sampling and testing of aggregates shall be as per IS: 2386 under the
supervision of ENGINEER. The cost of all tests, sampling, etc. shall be borne
by CONTRACTOR.
4.7.4 Water to be used shall be tested to comply with clause 5.4 of IS: 456.
4.7.5 CONTRACTOR shall furnish manufacturer’s test certificates and technical
literature for the admixture proposed to be used. If directed, the admixture shall
be got tested at an approved laboratory at no extra cost.
4.8 STORING OF MATERIALS
4.8.1 All material shall be stored in a manner to prevent its deterioration and
contamination, which would preclude its use in the works. Requirements of IS:
4082 shall be complied with.
4.8.2 CONTRACTOR shall make his own arrangements for the storage of adequate
quantity of cement even if cement is supplied by OWNER. If such cement is
not stored properly and has deteriorated, the material shall be rejected. Cost of
such rejected cement, where cement is supplied by OWNER, shall be
recovered at issue rate or open market rate whichever is higher. Cement bags
shall be stored in dry weatherproof shed with a raised floor, well away from the
outer walls and insulated from the floor to avoid moisture from ground. Not
more than 15 bags shall be stacked in any tier. Storage arrangement shall be
approved by ENGINEER. Storage under tarpaulins shall not be permitted. Each
consignment of cement shall be stored separately and consumed in its order
of receipt. CONTRACTOR shall maintain record of receipt and consumption of
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4.8.3 Each size of coarse and fine aggregates shall be stacked separately and shall
be protected from dropping leaves and contamination with foreign material. The
stacks shall be on hard, clean, free draining bases, draining away from the
concrete mixing area.
4.8.4 CONTRACTOR shall make his own arrangements for storing water at site in
tanks of approved capacity. The tanks shall be cleaned at least once a week to
prevent contamination.
4.8.5 The reinforcement shall be stacked on top of timber sleepers to avoid contact
with ground/ water. Each type and size shall be stacked separately.
5.0 CONCRETE
5.1 GENERAL
5.1.1 Concrete grade shall be as designated on drawings. Concrete in the works shall
be “DESIGN MIX CONCRETE” or “NOMINAL MIX CONCRETE”. All concrete
works of up to grade M15 shall be NOMINAL MIX CONCRETE whereas all
other grades, M20 and above, shall be DESIGN MIX CONCRETE.
5.2 DESIGN MIX CONCRETE
5.2.1 For this specification, Design Mix Concrete is classified as "Normal Concrete".
It shall be identified by a prefix and two numbers. Prefix "M" would denote
Normal Concrete. The two numbers e.g. 25 - 40 would denote the crushing
strength of cube at 28 days in N/mm2 and maximum size of the coarse
aggregates in millimeters respectively. Normal concrete shall have a net dry
unit weight of not less than 25 kN/m3, for the finished structure after curing.
5.2.2 Mix Design and Testing
For Design Mix Concrete, the mix shall be designed as per IS 10262 to provide
the grade of concrete having the required workability and characteristic
strength not less than appropriate values given in IS: 456. The design mix shall
in addition be such that it is cohesive and does not segregate during placement
and should result in a dense and durable concrete capable of giving the
specified finish. For liquid retaining structures, the mix shall also result in
watertight concrete. The CONTRACTOR shall exercise great care while
designing the concrete mix and executing the works to achieve the desired
result.
5.2.3 The minimum grade of concrete shall be as per Table 5 of IS: 456 for various
exposure conditions of concrete. For various environmental conditions, refer to
Table 3 of IS: 456.
5.2.4 The minimum cement content for Design Mix Concrete shall be as given in IS
456.
The minimum cement content stipulated IN IS 456applies to 20 mm nominal
maximum size aggregate. For other sizes of aggregate, the minimum cement
content shall be changed as per Table 6 of IS: 456. The CONTRACTOR’s
quoted rates for concrete shall provide for the above eventuality and nothing
extra shall become payable to the CONTRACTOR on this account. Even in the
case where the quantity of cement required is higher than that specified above
to achieve desired strength based on an approved mix design, nothing extra
shall become payable to the CONTRACTOR.
Cement content not including fly-ash and GGBS more than 450 kg/m3 should
not be used unless special consideration has been given in design to the
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increased risk of cracking due to shrinkage in thin sections, or to early thermal
cracking and to the increased risk of damage due to alkali silica reactions.
5.2.5 The quantity of maximum mixing water per unit volume of concrete may be
determined from Table 2 of IS 10262.The water content in Table 2 is for angular
coarse aggregate and for 25 to 50 mm slump range. The water estimate in
Table 2 can be reduced by approximately 10 kg for sub- angular aggregates,20
kg for gravel with some crushed particles and 25 kg for rounded gravel to
produce same workability. For the desired workability (other than 25 to 50 mm
slump range),the required water content may be established by trial or an
increase by about 3 percent for every additional 25 mm slump or alternatively
by use of chemical admixtures conforming to IS 9103.Water reducing
admixtures or super plasticizing admixtures usually decrease water content by
5 to 10 percent and 20 percent and above respectively at appropriate dosages.
5.2.6 It shall be CONTRACTOR’s sole responsibility to carry out the mix designs at
his own cost. He shall furnish to ENGINEER for approval at least 30 days
before concreting operations, a statement of proportions proposed to be used
for the various concrete mixes and the strength results obtained. The strength
requirements of the concrete mixes ascertained on 150 mm cubes as per IS:
516 shall comply with the requirements of Table – 2 of IS: 456.
5.2.7 A random sampling procedure shall be adopted to ensure that each concrete
batch shall have a reasonable chance of being tested i.e., the sampling should
be spread over the entire period of concreting and cover all mixing units. The
minimum frequency of sampling of concrete of each grade shall be in
accordance with the cl. 15.2 of IS 456.:
3 test specimens (cubes) shall be made for each sample for testing at 28 days.
The test results of the sample shall be the average of the strength of 3
specimens.
5.2.8 In the ‘very low’ category of workability where strict control is necessary, for
example pavement quality concrete, measurement of workability by
determination of compacting factor will be more appropriate than slump (refer
to IS: 1199) and a value of compacting factor of 0.75 to 0.80 is suggested.
5.2.9 In the ‘very high’ category of workability, measurement of workability by
determination of flow will be appropriate (refer to IS: 9103).
5.2.10 Where single size graded coarse aggregate are not available, aggregates of
different sizes shall be properly combined. The CONTRACTOR’s mix design
shall show that combined grading of coarse aggregate meets the requirements
of Table 2 of IS: 383 for graded aggregates.
5.3 BATCHING AND MIXING OF CONCRETE
5.3.1 Proportions of aggregates and cement, as per approved concrete mix design,
shall be by weight. These proportions shall be maintained during subsequent
concrete batching by means of weigh batchers capable of controlling the
weights within ±2% for cement and ±3% for aggregate. The batching equipment
shall be calibrated at the frequency decided by ENGINEER.
5.3.2 Amount of water added shall be such as to produce dense concrete of required
consistency, specified strength and satisfactory workability and shall be so
adjusted to account for moisture content in the aggregates. Water- cement ratio
specified for use by ENGINEER shall be maintained. Each time the work stops,
the mixer shall be cleaned out, and while recommencing, the first batch shall
have 10% additional sand and cement to allow for sticking in the drum.
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5.3.3 Arrangement should be made by CONTRACTOR to have the cubes tested at
his own expense in an approved laboratory or in field with prior consent of
ENGINEER. Sampling and testing of strength and workability of concrete shall
be as per IS: 1199, IS: 516 and IS: 456. It is preferable to cast additional cubes
(minimum 3 specimens) for testing at 7 days and 14 days.
6.0 NOMINAL MIX CONCRETE
6.1 MIX DESIGN AND TESTING
Mix Design and preliminary tests are not necessary for Nominal Mix Concrete.
However, works tests shall be carried out as per IS: 456. Proportions for
Nominal Mix Concrete and water-cement ratio may be adopted as per Table 9
of IS: 456. However, it will be CONTRACTOR’s sole responsibility to adopt
appropriate nominal mix proportions to achieve the specified characteristic
strength, if required or directed by the ENGINEER..
6.2 BATCHING AND MIXING OF CONCRETE
Based on the adopted nominal mixes, aggregates shall be measured by
volume. However, cement shall be by weight only. Appropriate correction shall
be made for bulking of sand after testing.
7.0 READY MIXED CONCRETE
7.1 All specification as per IS: 4926 – “Specification for Ready Mixed Concrete”
shall be applicable.
7.2 The CONTRACTOR shall identify at least two sources of Ready Mixed
Concrete supplier and get it approved by ENGINEER prior to start of the Works.
Any change in the source of the RMC, shall be got approved by the
ENGINEER.
7.3 The design mix prepared by the RMC supplier shall be the responsibility of the
CONTRACTOR. The testing of concrete as per Codal provisions and the
specifications shall be done by the CONTRACTOR same as the normal
concreting works.
8.0 PRECAST CONCRETE
8.1 GENERAL
8.1.1 Precast concrete shall comply with the preceding Sections relating to Concrete
as far as they are applicable.
8.1.2 Precast concrete manufacture, striking of shutters, curing, lifting, handling,
storage, transportation and installation shall comply with the requirements as
specified herein after.
8.2 PRECASTING BED
8.2.1 All precast units shall be cast on, or their shutters supported from a suitably
prepared level unyielding area.
8.3 MARKING
8.4 FORMWORK
8.4.1 The formwork shall be either steel or lined with steel, waterproof/ laminated
board or such other material as directed and approved by the ENGINEER.
Forms shall be strongly constructed, closely jointed and smooth and shall be
such as to ensure true sharp arises and a perfect surface. Forms shall be so
designed that they can be taken apart and reassembled readily.
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Surface Finish of precast units shall comply with requirements of clause 21.0
of this specification. The class of Finish shall generally be of F2 type unless
detailed differently on the drawings or as directed by the ENGINEER. No
construction joints will be permitted within any precast work.
8.5 CASTING TOLERANCE
8.5.1 The casting tolerance, unless otherwise ordered or directed, shall be within +3
mm of true dimensions.
8.6 STRIKING FORMS
8.6.1 The method and time of striking the side shutters after casting the units will
normally be left to the discretion of the CONTRACTOR, but the ENGINEER
may specify minimum time in which case the CONTRACTOR must comply with
the ENGINEER's directions. In the event of any damage resulting from
premature removal of shutters, or from any other cause, the unit will be liable
to rejection and replacement by the CONTRACTOR at his own cost, whether
the ENGINEER has specified a minimum striking time or not.
8.7 LIFTING, STACKING AND REMOVAL
8.7.1 Precast units shall not be lifted, transported or used in the Works until they are
sufficiently mature. The crushing tests on the test cubes, which are to be kept
along with the relevant precast units, will be used to assess the maturity of the
units.
8.7.2 Lifting, stacking and removal of precast units shall be undertaken without
causing shock, vibration or undue stress to or in the units. The CONTRACTOR
shall satisfy the ENGINEER that the methods he proposes for lifting,
transporting and setting precast units will not overstress or damage the units in
any way. In the event of overstress or damage due to whatever cause, the unit
or units concerned will be liable to rejection. Rejected units shall be immediately
broken up and removed from the site. The CONTRACTOR shall replace such
rejected units at his own cost.
8.8 CURING
8.8.1 The top and sides of all precast units shall be kept covered constantly and in a
damp condition with clean, potable fresh water for at least seven days after
casting or for such further period as the ENGINEER may direct. It is preferable
to have a curing pond for this purpose.
8.9 PRECASTING RECORDS
The CONTRACTOR shall maintain records for each unit, which shall include
the following:
(a) Type and reference number.
(b) Date of manufacture/ casting.
(c) Bed/ mould number.
(d) Curing method and duration.
(e) Date of removal from bed/ mould.
(f) Test Cube reference number and results.
(g) Date of placing in the Works.
(h) Location in the Works.
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These records shall be in a format agreed by the ENGINEER and shall always
be available for inspection. Copies of these records shall be supplied to the
ENGINEER on completion.
9.0 FORMWORK
9.1 Formwork shall be all inclusive and shall consist of but not limited to shores,
bracings, sides of footings, walls, beams and columns, bottom of slabs, etc.
including ties, anchors, hangers, inserts, falsework, wedges, etc.
9.2 The Design and Engineering of the formwork as well as its construction shall
be the responsibility of CONTRACTOR. However, if so directed by ENGINEER,
the drawings and calculations for the design of the formwork shall be submitted
to ENGINEER for approval.
9.3 Formwork shall be designed to fulfil the following requirements:
9.3.1 Sufficiently rigid and tight to prevent loss of grout or mortar from the concrete
at all stages and appropriate to the methods of placing and compacting.
9.3.2 Capable of providing concrete of the correct shape and surface finish within the
specified tolerance limits as given in clause 11.1 of IS 456.
9.4 The formwork may be of lined timber, waterproof/ plastic coated plywood, steel,
plastic depending upon the type of finish specified. Sliding forms and slip form
may be used with the approval of ENGINEER. Timber for formwork shall be
well seasoned, free from sap, shakes, loose knots, worm holes, warps and
other surface defects. Joints between formwork and formwork and between
formwork and structure shall be sufficiently tight to prevent loss of slurry from
concrete using foam and rubber seals.
9.5 The faces of formwork coming in contact with concrete shall be cleaned and
two coats of approved mould oil applied before fixing reinforcement. All
rubbish, particularly chippings, shavings, sawdust, wire pieces, dust, etc. shall
be removed from the interior of the forms before the concrete is placed. Where
directed, cleaning of forms shall be done by blasting with a jet of compressed
air at no extra cost.
9.6 Forms intended for reuse shall be approved by the ENGINEER.
CONTRACTOR shall equip himself with enough quantity of shuttering to allow
for wastage to complete the job in time.
9.7 Permanent formwork shall be checked for its durability and compatibility with
adjoining concrete before it is used in the structure. It shall be properly
anchored to the concrete.
9.8 For liquid retaining structures sleeves shall not be provided for through bolts
nor shall through bolts be removed if provided. The bolts, in the latter case,
shall be cut at 25 mm depth from the surface and the hole made good by
cement mortar of the same proportion as the concrete just after striking the
formwork.
9.9 Forms for substructure may be omitted when, in the opinion of ENGINEER, the
open excavation is firm enough (in hard non-porous soils) to act as a form.
Such excavation shall be slightly larger, as directed by ENGINEER, than that
required as per drawing to compensate for irregularities in excavation.
9.10 Formwork showing excessive distortion, during any stage of construction, shall
be removed. Placed concrete affected by faulty formwork, shall be entirely
removed and formwork corrected prior to placement of new concrete at
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9.11 The striking time for formwork shall be determined based on the following
requirements:
(a) Development of adequate concrete strength;
(b) Permissible deflection at time of striking formwork;
(c) Curing procedure employed - its efficiency and effectiveness;
(d) Subsequent surface treatment to be done;
(e) Prevention of thermal cracking at re-entrant angles;
(f) Ambient temperatures and aggressiveness of the environment (unless
immediate adequate steps are taken to prevent damage to the concrete).
Before removing formwork of soffit of slabs/ beams compressive strength at 7/
14/ 21 days shall be checked.
9.12 Under normal circumstances (generally where temperatures are above 200
Celsius) forms may be struck after expiry of the period given in IS: 456 unless
directed otherwise by ENGINEER. For Portland Pozzolana/ Slag Cement the
stripping time shall be suitably modified as directed by the ENGINEER. It is the
CONTRACTOR’s responsibility to ensure that forms are not struck until the
concrete has developed sufficient strength to support itself, does not undergo
excessive deformation and resists surface damage and any stresses arising
during the construction period.
10.0 REINFORCEMENT FABRICATION AND PLACEMENT
10.1 Reinforcing bars shall be bent and fixed in accordance with the procedure
specified in IS 2502.
10.2 All bars shall be bent by Bar bending machines.
10.3 Re-bending or straightening incorrectly bent bars shall not be done without
approval of ENGINEER.
10.4 Reinforcement shall be accurately fixed and maintained firmly in the correct
position using blocks, spacers, chairs, binding wire, etc. to prevent
displacement during placing and compaction of concrete in accordance with
clause 12.3 to 12.6 of IS 456. The tied in-place reinforcement shall be approved
by ENGINEER prior to concrete placement. PVC or concrete spacers of
appropriate size shall be used with the approval of ENGINEER.
10.5 Binding wire shall be 16-gauge soft annealed wire. Ends of the binding wire
shall be bent away from the concrete surface and in no case encroach into the
concrete cover.
10.6 Substitution of reinforcement, laps/ splices not shown on drawing shall be
proposed by CONTRACTOR and approved by ENGINEER.
10.7 If permitted by ENGINEER, welding of reinforcement shall be done in
accordance with IS: 2751, IS: 9417 and SP: 34 as applicable.
10.8 Tolerance on placement of reinforcement shall be as per Cl. 12.3 of IS: 456.
11.0 TOLERANCES
11.1 Tolerance for formed and concrete dimensions shall be as per IS: 456 unless
specified otherwise.
11.2 Tolerance is a specified permissible variation from lines, grade or dimensions
given in drawings. No tolerance specified for horizontal or vertical building lines
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boundaries. Unless otherwise specified, the following tolerances will be
permitted.
11.2.1 Tolerances for RC Buildings
(a) Variation from the Plumb
In the lines and surfaces of columns, piers, walls and in arises
i.
5 mm per 2.5 m or 25 mm, whichever is less.
ii. For exposed corner columns and other conspicuous lines.

In any bay or 5 m maximum - 5 mm
In 10 m or more - 10 mm
(b) Variation from the level or from the grades indicated on the drawings
i. In slab soffits, ceilings, beam soffits and in arises

In 2.5 m - 5 mm
For exposed lintels, sills, parapets, horizontal grooves and
ii.
other conspicuous lines
(c) Variation of the linear building lines from established position in plan
and related position of columns, wall and partitions
(d) Variation in the sizes and locations of sleeves, openings in walls and
floors - 5 mm except in the case of and for anchor bolts.
(e) Variation in cross-sectional dimensions of columns and beams and in
the thickness of slabs and walls
Minus - 5 mm
Plus - 10 mm
(f) Footings
i. Variation in dimension in plan

Minus - 5 mm
Plus - 50 mm
ii. Misplacement or eccentricity

2% of footing width in the direction of misplacement but not more than
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iii. Reduction in thickness

5% of specified thickness subject to
Minus -
a maximum of 50 mm
(g) Variation in steps
i. In a flight of stairs
Rise - 3 mm
Tread - 5 mm
ii. In consecutive steps

Rise - 1.5 mm
Tread - 3 mm
11.2.2 Tolerances in Other Structures
(a) All structures
Variation of the construction linear outline from established position in
i.
plan.
In 5 m - 10 mm
Variation of dimensions to individual structure features from established
ii.
positions.
In buried construction - 50 mm
Variations from plumb, from specified batter or from curved surfaces of
iii.
all structures.
In 2.5 m - 10 mm
In 5 m - 15 mm
In buried construction - Twice the above values
Variations from level or grade indicated on drawings in slabs, beams,
iv.
soffits, horizontal grooves and visible arises.
In 2.5 m - 5 mm
In 7.5 m or more - 10 mm
In buried construction - Twice the above values
Variation in cross-sectional dimensions of columns, beams, buttresses,
v.
piers and similar members.
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Plus - 10 mm
Variation in the thickness of slabs, walls, arch sections and similar
vi.
members.
Minus - 5 mm
Plus - 50 mm
11.2.3 Footing for Columns, Piers, Walls, Buttresses and Similar Members
i. Variation of dimension in Plan

Minus - 10 mm
Plus - 50 mm
ii. Misplacement or eccentricity

2% footing width in the direction of misplacement but not more than 50
mm
iii. Reduction in thickness

5% of specified thickness subject to a maximum of 50 mm
11.2.4 Tolerance in fixing Anchor Bolts shall be as follows:
i. Anchor bolts without sleeves : 1.5 mm in plan
ii. Anchor bolts with sleeves : 5.0 mm in elevation

- for bolts up to and including 28
: 5 mm in all directions
mm dia.
- for bolts up to 32 mm dia. : 3 mm in all directions
iii. Embedded parts : 5 mm in all directions
11.2.5 Tolerances in Formwork

The formwork shall be designed and constructed to the shapes, lines and
dimensions shown on the drawings within the tolerances given below:
Deviation from specified dimensions of
1. -6 mm
cross section of columns and beams
Deviations from dimensions of footings
(tolerances apply to concrete dimensions
2. +12 mm
only, not to positioning of vertical
reinforcing steel or dowels)
-12 mm
(a) Dimension in Plan
+50 mm
0.02 times the width of the footing
(b) Eccentricity in the direction of deviation, but not
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± 0.05 times the specified

(c) Thickness
thickness
11.3 Tolerance for top of concrete of equipment and structural steel foundations
shall be as under unless more stringent requirements are specified by
equipment manufacturer:
(a) Where grout thickness is less than or equal to 25 mm: ±5 mm.
(b) Where grout thickness is more than 25 mm: ±5 mm.
11.4 EXECUTION AND REMOVAL OF FORMS
(a) Before placing concrete, the surface of all forms shall be coated with
suitable non-staining form releasing agents such as raw linseed oil to
prevent adhesion of concrete and to facilitate removal of forms.
(b) The form releasing agent shall cover the forms fully and evenly without
excess over drip. Care shall be taken to prevent form releasing agents
from getting on the surface of the construction joints and on
reinforcement bars. Special care shall be taken to thoroughly cover form
strips for narrow grooves, to prevent swelling of the forms and the
consequent damage to concrete prior to or during removal of forms.
(c) Immediately before concrete is placed care shall be taken to see that all
forms are in proper alignment and the supports and fixtures are properly
secured and tightened.
(d) Where forms for continuous surfaces are placed in successive units, the
forms shall lap and fit tightly over the completed surface to prevent
leakage of cement slurry from the fresh concrete and to maintain
accurate alignment of the surface.
(e) Forms shall be left in place until their removal is authorised and shall
then be removed with care to avoid injury to concrete.
(f) Removal of forms shall be started when the concrete has achieved
strength of at least twice the stress to which the concrete may be
subjected at the time of removal of formwork.
(g) In normal circumstances and where ordinary Portland cement is used
forms can be allowed to be struck asper the guideline given in clause
11.3 of IS 456.
Note: Time shall be measured from last batch concreted in respect to the
structural member under consideration. For other cement stripping time as
recommended above may be suitably decided by ENGINEER.
Re-propping shall be done to the below floor to carry the construction load
transferred through props/ equipment, etc. during construction of upper floor
and props left under till the period of removal of props supported to or any other
load due to construction load on the upper floor. Re-propping shall be part of
shuttering/ formwork for concrete without any claim for extra cost.
11.5 SETTLEMENT OF FORMWORK AND CAMBER
Due to various reasons such as closure of form joints, shrinkage of timber, dead
load deflections, elastic shortening of form members or formwork, deflections,
settlement may occur. The CONTRACTOR shall take precautions, including
using adequately rigid formwork, to prevent excessive settlement/ deflection;
the usual acceptable limit being 1/500 of the spans of the formwork.
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In the absence of any specified camber on the drawings, soffit of all beams
more than 5 m in span and other than pre-stressed concrete beams shall be
laid to a camber, the amount of which at mid span shall not be less than 1/500
of the span of the structure. The profile of soffit shall be parabolic.
12.0 PREPARATION PRIOR TO CONCRETE PLACEMENT
12.1 The faces of formwork coming in contact with concrete shall be cleaned and
two coats of approved mould oil applied before fixing reinforcement. All
rubbish, particularly chippings, shavings, sawdust, wire pieces, dust, etc. shall
be removed from the interior of the forms before the concrete is placed. Where
directed, cleaning of forms shall be done by blasting with a jet of compressed
air at no extra cost.
12.2 All arrangements - formwork, equipment and proposed procedure, shall be
approved by ENGINEER. CONTRACTOR shall maintain separate Pour Card
for each pour as per the format enclosed.
13.0 TRANSPORTING, PLACING AND COMPACTING CONCRETE
13.1 Concrete shall be transported from the mixing plant to the formwork with
minimum time lapse by methods that shall maintain the required workability and
will prevent segregation, loss of any ingredients or ingress of foreign matter or
water.
13.2 In all cases concrete shall be deposited as nearly as practicable directly in its
final position. For locations where, direct placement is not possible and in
narrow forms, CONTRACTOR shall provide suitable drops and “Elephant
Trunks”. Concrete shall not be dropped from a height of more than 1.5 m.
13.3 Concrete shall not be placed in flowing water. Under water concrete shall be
placed in position by tremie or by pipeline from the mixer and shall never be
allowed to fall freely through the water.
13.4 While placing concrete the CONTRACTOR shall proceed as specified below
and ensure the following:
(a) Continuously between construction joints and predetermined
abutments.
(b) Without disturbance to forms or reinforcement.
(c) Without disturbance to embedment.
(d) Without dropping in a manner that could cause segregation or shock.
(e) In deep pours only when the concrete and formwork is designed for this
purpose and by using suitable chutes or pipes.
(f) Do not place if the workability is such that full compaction cannot be
achieved.
(g) Without disturbing the unsupported sides of excavations; prevent
contamination of concrete with earth. Provide sheeting, if necessary. In
supported excavations, withdraw the linings progressively as concrete
is placed.
(h) If placed directly onto hardcore or any other porous material, dampen
the surface to reduce loss of water from the concrete.
(i) Ensure that there is no damage or displacement to sheet membranes.
(j) Record the time and location of placing structural concrete.
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(k) When concrete is brought from batching plant to site in millers, the time
of mixing and the time of pour shall be checked to ensure that setting
has not started.
13.5 Concrete shall normally be poured & compacted in its final position within initial
setting time. Concrete shall be compacted during placing with approved
vibrating equipment without causing segregation until it forms a solid mass free
from voids, thoroughly worked around reinforcement and embedded fixtures
and into all corners of the formwork. When placing concrete in layers advancing
horizontally, care shall be taken to ensure adequate vibration, blending and
melding of the concrete between successive layers. Vibrators shall not be
allowed to come in contact with reinforcement, formwork and finished surfaces
after start of initial set. Over-vibration leads to segregation and shall be
avoided.
13.6 Concrete may be conveyed and placed by mechanically operated equipment
after getting the complete procedure approved by ENGINEER. The slump shall
be held to the minimum necessary for conveying concrete by this method.
When concrete is to be pumped, the concrete mix shall be specially designed
to suit pumping. Care shall be taken to avoid stoppages in work once pumping
has started.
13.7 CONTRACTOR shall submit a method statement to ENGINEER for approval,
furnishing details of pour sequence, thickness of each layer, mixing and
conveying equipment proposed, etc. preferably with a sketch.
13.8 Except when placing with slip forms, each placement of concrete in multiple lift
work, shall be allowed to set for at least 24 hours after the final set of concrete
before the start of subsequent placement. Placing shall stop when concrete
reaches the top of the opening in walls or bottom surface of slab, in slab and
beam construction, and it shall be resumed before concrete takes initial set but
not until it has had time to settle as determined by ENGINEER. Concrete shall
be protected against damage until final acceptance.
14.0 PLACING OF CONCRETE BY PUMPING METHODS
14.1 GENERAL
14.1.1 Placing of concrete by pumping will be as specified or authorised by
ENGINEER to achieve the required speediness of construction and maintain
targeted schedules.
14.1.2 Pumping of concrete shall be done only after conducting pumpability trials to
ascertain the performance of fresh concrete on pumping in presence of the
ENGINEER as per approved procedure. During pumping, concrete shall be
conveyed either through rigid pipe or through flexible hose and discharged
directly into the desired area. A steady supply of pumpable concrete is
necessary for satisfactory pumping. Pumpable concrete requires properly
graded aggregates, material uniformity, consistent batching and thorough
mixing. They shall be used for concreting densely reinforced structures, internal
structural elements of buildings and for large pours of concrete. Concrete
pumps used shall be able to deliver concrete over a horizontal and vertical
distance as per the directives of the ENGINEER.
14.1.3 Placement of normal concrete by pumping will be permitted as specified or
authorised by the ENGINEER. The decision, whether to pump any mix shall
rest entirely with the ENGINEER and no extra claims for payment on this
account will be entertained. The pumping equipment, pipe lines and
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conform to the recommendations of ACI-304.2R (latest revision) – Placing of
concrete by pumping method - Proportioning of pumpable mixes gives certain
guide lines on concrete mix. However, final selection of mix shall be as
instructed by the ENGINEER.
14.2 PUMPING EQUIPMENT
14.2.1 Requisite number of modern dependable concrete pumps capable of pumping
concrete of specified quality at a rate required to meet the construction
schedules, together with a balanced complement of pipelines, accessories,
spare parts, power controlled placing booms, and experienced pump operators
and maintenance staff shall be provided at locations and in a manner approved
by the ENGINEER.
14.2.2 The pumping plant shall be completely installed on each occasion, with
preliminary mock operation for a sufficient length of time prior to scheduled
placement of a concrete pour, to enable the ENGINEER to conduct pumpability
tests and necessary adjustments for the concrete mix, prior to use of the
pumping for placement of concrete.
14.3 PROPORTIONING PUMPABLE CONCRETE
14.7.1 Basic Consideration
(a) Although the ingredients of concrete to be placed both by pumping and
by other means are the same, more emphasis shall be laid on the
quality control and proportioning of a dependable pumpable mix.
Dependability is ensured by the equipment and the operator, with the
control of all the ingredients in the mixture, the batching and mixing
operations, and the knowledge and experience of all the personnel from
beginning to end.
(b) Concrete mixes for pumping shall be “plastic” at all times. Stiff mixes
shall not be used for pumping as they do not pump well. Attention shall
be given to the mortar (cement, sand and water) and the amounts and
sizes of coarse aggregates.
14.4 NORMAL WEIGHT AGGREGATES
14.8.1 Coarse Normal Weight Aggregates
The maximum size of angular coarse aggregate shall be limited to one-third of
the smallest inside diameter of the hose or pipe based on simple geometry of
cubical shape aggregates. For well-rounded aggregates, the maximum size
shall be limited to 40% of the pipe or hose diameter. Adequate provisions shall
be made to eliminate over size particles in the concrete by screening or by
careful selection of aggregate. Gradation of sizes of coarse aggregates shall
correspond to Grades A and B of Table-1 and shall meet IS: 2386
requirements. If required, certain fractional sizes shall be combined and
blended to produce the required gradation. Greater emphasis shall be laid on
uniformity of gradation throughout the entire job.
The maximum size of the coarse aggregate has a significant effect on the
volume or amount of coarse aggregate that may be effectively used in a mix.
As will be seen from Table-2 the quantity of coarse aggregate must be
substantially reduced as the maximum size becomes smaller. Mixes consisting
of too large a portion of coarse aggregate with less cement shall be avoided.
Table-1
Grading Requirement of Coarse Aggregates for Pumped Concrete
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Percent Passing Percent Passing

Sieve Size Sieve Size
by Weight by Weight
50 mm 100 25 mm 100
40 mm 95 to 100 20 mm 90 to 100
20 mm 35 to 70 12.50 mm 20 to 55
10 mm 10 to 30 10 mm 0 to 15
4.75 mm 0 to 5 4.75 mm 0 to 5
Table-2
Volume of Coarse Aggregate per unit of Volume of Concrete
Grade – A (Maximum Size 40 mm) Grade – B (Maximum Size 20 mm)
Volume of Dry-rodded Coarse Aggregate per Unit Volume of
Maximum Size
Aggregates of Concrete for different Fineness Moduli of sand
FMS = 2.40 FMS = 2.60 FMS = 2.80 FMS = 3.00
10 0.50 0.48 0.46 0.44
12.50 0.59 0.57 0.55 0.53
20 0.66 0.64 0.62 0.60
25 0.71 0.69 0.67 0.65
40 0.76 0.74 0.72 0.70
50 0.78 0.76 0.74 0.72
Notes:
1. Volumes are based on aggregates in dry-rodded condition.
2. These volumes are selected from empirical relationships to produce
concrete with a degree of workability suitable for usual reinforced
construction. When placement is to by pump, they shall be reduced by
about 10 percent.
3. FMS = Fineness Modulus of Sand.
14.8.2 Fine Normal Weight Aggregate
Fine aggregate shall consist of natural sand, manufactured sand or a
combination thereof and shall be graded within the following limits:
Sieve Size Percent passing by Weight
9.50 mm 100
4.75 mm 95 to 100
2.36 mm 80 to 100
1.18 mm 50 to 85
600 microns 25 to 60
300 microns 10 to 30
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Fine aggregates shall conform to the requirements of IS: 2386. Attention shall
be given to those passing through finer screen sizes. For small line system
(less than 150 mm) 15 to 30% shall pass 300-micron sieve and 5 to 10% shall
pass 150-micron sieve. Sands, which are deficient in either of these two sizes
shall be blended with selected finer sands or inert material such as quarry dust
to produce these desired percentages.
The fineness modulus of sand meeting the above grading limits will fall between
2.13 and 3.37 with the median being 2.75. Pumpability of mixes will generally
improve with a decrease in the fineness modulus value or in other words with
the use of finer sands. Sands having a fineness modulus between 2.40 and
3.00 are generally satisfactory provided that the percentages passing 300
micron and 150-micron sieves meet the previously stated requirements. It shall
also be emphasised that for uniformity, the fineness modulus of the sand shall
not vary more than 0.20 from the average value used in proportioning.
Table-2 is suggested as a guide to determine the amounts of coarse aggregate
to be combined with sand of different fineness modulus. The foot notes of
Table-2 require a reduction in the volume of coarse aggregate by 10% for
pumping. This margin shall be considered as a safety margin for variations in
sand gradation to reduce pumping pressure. Under conditions of good
materials control and uncomplicated line systems, this reduction may not be
required.
Although in practice it may not be possible to duplicate this recommended sand
gradation exactly, sands having a gradation closer to the upper limit (fine sand)
are more desirable for pumping than those near the lower limit (coarse sand).
The fineness modulus of sand according to the recommended curve is 2.68
and the gradation meets all the requirements stated earlier.
14.5 WATER AND SLUMP
14.9.1 Water requirements and slump control for pumpable normal weight concrete
are interrelated and extremely important considerations. The mixing water
requirements for a mix shall be determined by the ENGINEER and modified to
suit the fineness of sands, quality of admixtures, additives, cement
replacements or other special materials being used in the concrete.
14.9.2 The CONTRACTOR shall establish the optimum slump jointly with the
ENGINEER for a pumpable mix at the discharge hose end and shall maintain
control of that slump throughout the course of a job. Excess water shall not be
added in the receiving hopper to make the concrete mix pumpable, instead
attempt shall be made to obtain ‘truly plastic mix’ by proper proportioning.
14.9.3 Slump of concrete may undergo change between initial mixing and final
placement. If the slump at the discharge hose end are to be maintained within
specified limits, it will be necessary for the concrete to enter the pump at a
higher slump to give the required mobility during transport. Slump adjustments
by re-proportioning of the constituents as may be required shall be carried out
by the CONTRACTOR jointly in consultation with the ENGINEER for every type
of mix and for every new placement and set up of pump and pipelines.
14.6 CEMENT CONTENT
(a) The determination of the cement content for a normal weight pump mix
shall follow the same basic principles used for conventionally placed
concrete. The water cement ratio shall be established by the
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of slightly higher ranges of slump and ratios of fine to coarse
aggregates, the pump mix may require an increase in the amount of
cement above those pumpable concrete mass. The total quantity of
fines passing through the 300-micron sieve including cement, fine sand,
stone dust, etc. shall be in the range of 380 to 450 kg/cum of concrete.
(b) Cement content in case of M50 shall be maximum of 425 kg/cum, and
shall be a mix with high range of workability i.e. 175 mm +/- 25 mm. All
the contents shall be mixed based on the mix design and trial studies.
(c) While establishing the cement content for normal weight trial mixes, it
will be necessary to consider the capabilities of the pump and its
operator for over strength proportioning in the laboratory to provide for
field variations.
(d) In case of pumping difficulties, it is desirable and economical to correct
any deficiencies in the aggregates, especially in the sand instead of
using extra quantities of sand. With well graded coarse and fine
aggregates properly combined, the cement requirement for pumpable
mixes shall closely resemble to those used in conventionally placed
concrete.
14.7 ADMIXTURES
The use of poor aggregate grading or aggregate with continuous change in
overall grading of the ‘combinations’ during concreting operation will make
special admixtures quite useful in overcoming the main difficulty like blockage
in pumping. These admixtures shall be incorporated in pumpable concrete to
achieve the following.
(a) Increase in the range of mix designs, which may be successfully
pumped using water reducing admixtures/ super plasticisers with the
approval of the ENGINEER.
(b) Reducing the risk of pipeline blockages by preventing segregation of
concrete mix.
(c) To have satisfactory/ specified performance both in fresh and hardened
state.
Any admixture that increases workability in normal weight concrete may usually
improve pumpability. The choice of type of admixture and the advantage gained
from its use in concrete to be pumped will depend on the characteristics of the
pump mix and will be finally decided by the ENGINEER in consultation with the
admixture manufacturer.
For improvement of pumpability the following admixtures are generally
recommended. Such admixtures used shall conform to ASTM C-494/ IS: 9103:
(a) Water Reducing Admixtures/ Super Plasticisers
These cause reduction in water requirements at constant slump or an
increase in slump at constant water-cement ratio. They can be designed
to have no apparent effect on setting time, or alternately to achieve
varying degrees of acceleration or retardation in rate of hardening of the
mixture. Most water reducing admixtures increase the palpability of the
concrete mix through plasticising action.
(b) Air Entraining Admixtures
Air entrained concrete is considerably plastic and more workable than
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aggregate segregation and has less tendency for concrete to bleed.
Start-up after shutting down is also generally easier due to reduced
bleeding. For pumped concrete these limits shall be obtained at the
point of placement in the structure. To compensate for air content loss
in the air entrained concrete higher entrainment of air may be required
at the batching plant. The required adjustment of admixture dose shall
be carried out by the ENGINEER after carrying out necessary air loss
tests. An air content in the range of 3 to 5% shall be preferred as higher
ranges reduces the delivery capacity of pump systems due to increased
compressibility of the concrete and reduces strength of concrete.
If air-entraining plasticiser is used, typically 13% minimum water
reduction is possible. Therefore, strength loss due to air entrainment
will be compensated by using such air-entraining plasticiser.
(c) Finely Divided Mineral Admixtures
CONTRACTOR, if specifically approved by the ENGINEER, can use
mineral admixture. In concrete mixtures, deficient in fines, the addition
of a finely divided inert mineral admixture generally improves
workability, pumpability, reduces the amount of bleeding and increases
the strength. The effect on strength depends on the type of mineral
admixture used, conditions under which the concrete is cured, and the
amount of admixture used. Water soluble polymers obtained from
cellulose derivations may also be used as an admixture with a small
dose of 60 to 150 gms/cum to increase viscosity of the mixing water and
reduce the frictional resistance to flow and bleeding in the pipe system.
14.8 TRIAL MIXES
The trial mixes for pumping shall be prepared and tested in the Site laboratory
by CONTRACTOR in accordance with clause 14.9 of this specification. The
ingredients, particularly the coarse and fine aggregates shall also be checked
for the conformance to the desired properties described, by the
CONTRACTOR. Table-2 may be used to select the volume of coarse
aggregate per cum of concrete. In using this Table, it is recommended that the
highest probable fineness modulus of sand be used rather than the average
fineness modulus to ensure consistent performance during pumping. For
additional plasticity, 10% reduction in coarse aggregate quantities shall be
considered. Experience with the use of local aggregate and their uniformity
shall also be considered in the proportioning concepts.
14.9 MIX DESIGN FOR PUMPABLE CONCRETE
Taking the above factors into account, the concrete shall first be designed for
normal placement conditions and then modified as necessary to suit pumping.
The following procedure shall be adopted:
(a) Design the mix for specified characteristic strength and workability.
(b) Check and ensure combined grading of aggregates i.e. as uniform
grading as possible. This requirement is vital as gaps or partial gaps
are the basic reasons for poor water retention property and segregation
under pressure.
(c) Determine the optimum sand content for the required workability and
increase sand content by reducing volume of coarse aggregate per unit
volume of concrete by about 10% as a degree of protection against
under sanding due to batch variations.
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(d) Recheck the minimum cement content for durability.
(e) Examine the total fines content i.e. cement and fine aggregates passing
through 300-micron sieve and readjust the mix, if necessary. A very rich
mix with fine sand will be as problematic as a coarse sand with lean
mix.
(f) Re-appraise the grading if the particle shape of any fraction is such as
may cause excessive voids. Re-adjust as required, if necessary
examining the void ratio of various combinations, using void meter to
achieve minimum voids at the expense of ‘sufficient fines’ content.
(g) If dissatisfied with (a) to (f) as above, consider what remedial action may
be taken to overcome the troublesome factor. For example, the
following two situations may occur:
If the sand has coarser fraction it is worth considering the addition of a
proportion of finer sand, or alternately if the sand has finer fraction, the
addition of coarse fraction may be considered. Addition or reduction of
cement may help, but the correct solution is to overcome the gap in
overall grading as stated above.
(h) In a 20 mm aggregate maximum size, if there is an excess of 10 to 4.75
mm fraction, and this fraction is flaky with unduly large surface area,
either increase the sand content to reduce the possibility of segregation
and to reduce the inter-practical stresses, or (better) re-grade using
single sized aggregates.
(i) At the trial mix stage small variations can be made preferably in the light
of the pressures registered and observed performances through the
pump. In certain cases, admixtures may be economically and
beneficially used to improve or eliminate circumstances that cannot
readily be overcome by other means.
14.10 TESTING FOR PUMPABILITY
No mix shall be accepted for use on a pumping job until an actual test under
field condition has been completed. Testing a mix for pumpability involves
duplication of the anticipated job condition from beginning to end. The batching
and conveying by truck mixers shall be the same as will be used, the same
pump and operator shall be present. The pipe and hose layouts shall simulate
the actual condition as far as practicable. Prior use of a mix on another job may
furnish evidence of pumpability, but only if conditions are duplicated. Before
commencing a new concreting job, the CONTRACTOR shall carry out
pumpability tests in consultation with the ENGINEER. Concrete used in such
tests shall not be used in the actual construction, unless specifically permitted
by the ENGINEER.
Following parameters shall be established by pumpability trials:
(a) In-situ compressive and split tensile strength of concrete.
(b) Curing the sample at Site by sprinkling water.
(c) Curing the sample at Laboratory in curing tanks.
(d) Wet sieve analysis of concrete to ensure that proportions of ingredients
before and after pumping are same.
14.11 FIELD PRACTICES
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(a) Proper planning of concrete supply, pump location, line layout, placing
sequence and the entire pumping operation shall be done by the
CONTRACTOR and got approved by the ENGINEER on every
occasion before commencement of concreting job. The pump shall be
as near the placing area as practicable, and the entire surrounding area
must have adequate bearing strength to support the concrete delivery
trucks, thus assuring a continuous supply of concrete. For important
concrete placements and large jobs, adequate standby power and
pumping equipment shall be provided as replacement, should break
down occur.
(b) Direct communication shall be maintained between the pump operator,
concrete placing crew and batching plant. The placing rate shall be
estimated so that concrete can be operated at an appropriate delivery
rate. As a final check, the pump shall be started and operated without
concrete to ascertain that, all moving parts are operating properly. As
stated previously, the grout mortar shall be pumped into the line to
provide initial lubrication for the concrete. As soon as concrete is
received, the pump shall be run slowly until the lines are completely full
and the concrete is slowly moving. Once the pumping is started, the
operator shall ensure that the hopper of the pump is not emptied beyond
a certain level, as air may enter the pipeline and cause choking.
Continuous pumping should be ensured. If a delay occurs because of
concrete delivery, form repairs, or other factors, the pump shall be
slowed down to maintain some movement of the concrete till normal
supply is resumed. For longer delays, the concrete in the receiving
hopper shall be made to last as long as possible by moving the concrete
in the lines occasionally with one stroke of the pump. In confined areas,
attempt shall be made by the CONTRACTOR to run a return line back
to the pump, so that concrete can be re-circulated during delays.
(c) The CONTRACTOR shall ensure that obstructions are not found in the
pipe due to interruption in the feed of the concrete by more than 30 to
45 minutes.
(d) Minor blockages shall be cleared by operating a few strokes of the pump
in reverse momentarily and then by returning to normal forward
pumping. If this fails, a succession of reverse and forward strokes shall
be carried out to remove the blockage. Should this fail also, the
blockage may be due to air-lock and the entrapped air must be
removed.
(e) Attempt to push through the obstructions by repeatedly starting the
pump will result in compaction of the concrete and complicate the
removal of the concrete in the pipe. Blockages in the pipe are usually
discovered by the sound when the pipe is struck. To remove the
obstruction, the concrete pipe shall be taken apart at the assured
position and cleaned. Then the pumping process shall be started all
over again.
(f) This method of checking the blockage and setting it right shall be done
with great speed as excessive delay will cause setting of concrete in the
pipeline downstream of the choke and will lead to further blockage.
When the blockage is being found out and remedied, the pump shall
periodically be given one or two strokes forward to keep the concrete in
motion. If blockage occurs in the placer boom, a pipe joint near the base
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of the placer boom shall be opened and the boom made vertical to drain
the pipeline by gravity.
(g) Cleaning blockages are time consuming and as such major blockages
shall best be avoided by ensuring a pumpable mix. Concrete that is
either under or over sanded, short of fines, gap graded, has an excess
of a size, or excessively wet or dry will be rejected by the pump either
by blockage or by hard pumping involving excessive pressures.
(h) The termination of pumping operations shall be carefully planned to
utilise the concrete dormant in the pipeline and the hopper when the
pump is stopped and to avoid wastage.
(i) When the form is nearly full, and there is enough concrete in the line to
complete the placement, the pump shall be stopped, and a go-devil be
inserted and forced through the line to clear it out. Water under pressure
shall be used to push the go-devil. The go-devil shall be stopped about
one metre from the end of the line, so that the water in the line will not
spill over into the placement area. After flushing, water in the pipe shall
be removed by drain cock which shall be located for this purpose in the
lowest part of the line. After all concrete has been removed from the
lines, all lines and equipment shall be immediately cleaned thoroughly.
14.12 QUALITY CONTROL
(a) CONTRACTOR shall ensure that workmanship and plant shall be
maintained at peak efficiency. Degree of control on all the concrete
operation from selection of the ingredients to the final testing of
specimen shall be in line with the assumptions made in mix design with
respect to the standard deviation and co-efficient of variation.
(b) The CONTRACTOR shall ensure that any compromise in quality is not
done for the pumped concrete. To be pumpable, a high level of quality
control for the assurance of uniformity must be maintained. Sampling at
both the truck discharges and point of final placement shall be done by
the CONTRACTOR and the ENGINEER jointly, as frequently as the
ENGINEER desires to determine, if any change in the slump air content,
and other significant mix characteristics occur take necessary
corrective actions.
(c) The CONTRACTOR shall engage experienced supervision at all levels.
The placing crew shall be experienced and qualified and each operation
shall be well planned and properly scheduled.
(d) All the crew engaged in each of the concrete activities shall demonstrate
in the presence of the ENGINEER, their skills and capabilities to
produce the final product as specified.
15.0 MASS CONCRETE WORKS
15.1 Sequence of pouring for mass concrete works shall be as approved by
ENGINEER. CONTRACTOR shall exercise great care to prevent shrinkage
cracks and shall monitor the temperature of the placed concrete if directed.
16.0 PLACING TEMPERATURE OF CONCRETE
16.1 Placing temperature of concrete should be maintained as specified in Schedule
of Quantities or as directed by ENGINEER, to avoid shrinkage cracking.
16.2 Mixing water shall be kept cool by storing it under cover. Chilled water or
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temperature shall be used. For chilled water, it is recommended that the
CONTRACTOR install and maintain refrigeration facility of required capacity.
The CONTRACTOR shall also build and maintain well insulated adequate
capacity storage tank for cold water with insulated connected piping. To
supplement this refrigeration facility, the CONTRACTOR will have to have ice
plant or use commercial ice subject to approval of the ENGINEER. The full
quantity of crushed ice shall be stored in cold storage 24 hours in advance of
the start of concreting. The temperature in cold storage shall not be more than
-20 C. The CONTRACTOR should study the placing temperature condition and
work out plant capacity commensurate with the construction schedule
requirements and submit his scheme along with the tender.
16.3 Ice when used as replacement for a portion or all the mixing water shall be
produced from water, which meets the requirements of clause 4.3. Ice when
used shall be in flakes of size 3 mm or below or crushed condition and the
crushed ice shall be such as to pass completely, 10 mm sieve.
17.0 CURING
17.1 Curing and protection shall start immediately after the compaction of the
concrete to protect it from:
(a) Premature drying out, particularly by solar radiation and wind;
(b) Leaching out by rain and flowing water;
(c) Rapid cooling during the first few days after placing;
(d) High internal thermal gradients;
(e) Low temperature or frost;
(f) Vibration and impact, which may disrupt the concrete and interfere with
its bond to the reinforcement.
17.2 All concrete, unless directed otherwise by ENGINEER, shall be cured as
specified in clause 13.5 of IS 456. The quality of curing water shall be the same
as that used for mixing.
17.3 Where a curing membrane is directed to be used by the ENGINEER, the same
shall be of a non-wax base and shall not impair the concrete finish in any
manner. The curing compound to be used shall be got approved from the
ENGINEER before use and shall be applied with spraying equipment capable
of a smooth, even textured coat.
17.4 Curing may also be done by covering the surface with an impermeable material
such as polyethylene, which shall be well sealed and fastened.
17.5 Extra precautions shall be exercised in curing concrete during cold and hot
weather as per clause no. 8.3 of IS: 7861 (Part II) and clause no. 8.2 of IS:
7861 (Part I) respectively.
17.6 Curing arrangement shall be subjected to ENGINEER’s approval.
18.0 CONSTRUCTION JOINTS AND KEYS
18.1 Construction joints (location and type) shall be as shown on the drawing or as
approved by ENGINEER. Concrete shall be placed without interruption until
completion of work between construction joints. If stopping of concreting
becomes unavoidable anywhere, a properly formed construction joint shall be
made with the approval of ENGINEER.
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18.2 Dowels for concrete work, not likely to be taken up soon, shall be coated with
cement slurry and encased in lean concrete as indicated on the drawings or as
directed by ENGINEER.
18.3 Before resuming concreting on a surface, which has hardened all laitance and
loose aggregates shall be thoroughly removed by wire brushing and/ or
hacking, the surface washed with high pressure water jet and treated with thin
layer of cement slurry for vertical joints and a 15 mm thick layer of cement sand
mortar for horizontal joints, the ratio of cement and sand being the same as in
the concrete mix.
18.4 CONSTRUCTION JOINT TREATMENT (Alternate to clause 18.3)
Methodology stated herein under must be followed by CONTRACTOR
wherever instructed by the ENGINEER at no additional cost to the OWNER.
The entire construction joint shall be treated by green cutting using air/ water
jet at suitable pressure to remove the laitance from the green concrete surface
to receive subsequent pour over it. Suitable, approved brand of surface retarder
shall be used to retard the setting time of green concrete to a depth of 5 to 8
mm. Green cutting shall be done only after the final setting of concrete, so that
the additional water available from the air water jet used for green cutting on
the surface does not harm the quality of the concrete.
18.4.1 Application of Surface Retarder and Green Cutting at Construction Joint of
Concrete
18.4.1.1 Scope
Work under this procedure covers application of surface retarder over the green
concrete and green cutting the exposed surface of concrete after final setting
time to expose the aggregate, for proper bonding with fresh concrete of
successive pours.
18.4.1.2 Material Qualification
The surface retarder shall be qualified for use based on number of site trials/
mock-ups for achieving the desired surface after green cutting during different
ambient conditions.
18.4.1.3 Application
Surface retarder shall be applied uniformly with the help of agricultural spray
machine at the rate of 5 to 6 sqm/litre
1. Form panel at construction joint: Wherever the side of a pour is to
receive concrete later, a bulk head of such sides will be coated with
surface retarder at least one hour before the receipt of concrete.
2. For horizontal construction joints: Wherever the concrete is to be placed
above a pour, surface retarder shall be applied on the finished top
surface of the said pour within half an hour of finishing.
18.4.1.4 Green Cutting
Green cutting shall be started after final setting time of concrete to expose the
aggregate, for proper bonding with fresh concrete of successive pours. The
surface of concrete shall be green cut using air-water jet. Bunds shall be made
using cement mortar at convenient locations and cut out shall be made in the
side shutter to drain off excess water. All the laitance and green cut material
shall be removed from the green cut surface simultaneously.
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The time of green cutting shall be displayed on Tags, which will be placed at
appropriate locations so that said activity can be controlled in the proper way.
18.5 When concreting is to be resumed on a surface, which has not fully hardened,
all laitance shall be removed by wire brushing, the surface wetted, free water
removed, and a coat of cement slurry applied. On this a layer of concrete not
exceeding 150 mm thickness shall be placed and well rammed against the old
work. Thereafter work shall proceed in the normal way.
18.6 Approved epoxy Bonding agent, for bond between old (say 28 days or more)
and new concrete may also be used as per manufacturer’s specifications.
19.0 FOUNDATION BEDDING
19.1 All earth surfaces upon which or against which concrete is to be placed, shall
be well compacted and free from standing water, mud or debris. Soft or spongy
area shall be cleaned out and back filled with either soil-cement mixture, lean
concrete or clean sand compacted as directed by ENGINEER. The surfaces of
absorptive soils shall be moistened.
19.2 Concrete shall not be deposited on large sloping rock surfaces. The rock shall
be cut to form rough steps or benches by picking, barring or wedging. The rock
surface shall be kept wet for 2 to 4 hours before concreting.
20.0 BASE CONCRETE
20.1 The thickness and grade of concrete and reinforcement shall be as specified in
the item of work.
20.2 Before placing the blinding concrete of 1:4:8 mix, 50/75/100 mm thick as per
the item of work, the sub-base of rubble packing shall be properly wetted and
rammed. Concrete for the base shall then be deposited between the forms,
thoroughly tamped and the surface finished level with the top edges of the
forms. Two or three hours after the concrete has been laid in position, the
surface shall be roughened using steel wire brush to remove any scum or
laitance and swept clean so that the coarse aggregates are exposed. The
surface of the base concrete shall be left rough to provide adequate bond for
the floor finish to be provided later.
20.3 MEASUREMENT
Measurement shall be in sqm correct to two places of decimal. This work could
be either separate or combined along with the floor finish as indicated in the
respective items of work.
21.0 FINISHES
21.1 GENERAL
The formwork for concrete works shall be such as to give the finish as specified.
The CONTRACTOR shall make good as directed any unavoidable defects
consistent with the type of concrete and finish specified; defects due to bad
workmanship (e.g. damaged or misaligned forms, defective or poorly
compacted concrete) will not be accepted. CONTRACTOR shall construct the
formwork using the correct materials and to meet the requirements of the
design and to produce finished concrete to required dimensions, plumbs,
planes and finishes. Formed concrete surface finishes shall be as follows:
21.2 SURFACE FINISH TYPE F1
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up of loose or adhering debris. For surfaces below grade which will receive
waterproofing treatment the concrete shall be free of surface irregularities
which would interfere with proper and effective application of waterproofing
material specified for use.
This finish is formed for surfaces at construction joints. The surface produced
shall be free from voids, honeycombing or other large blemishes, steps, sharp
protrusions or local hollows. The shutters shall be removed as soon as possible
without disturbing the concrete or reinforcement and the surface shall be well
wire brushed and hosed down to remove all excess laitance and fine
aggregate. Coarse aggregate is to be left exposed but undisturbed.
The appearance shall be that of a smooth dense, well compacted concrete
showing the slight marks of well fitted shuttering joints. The Contractor shall
make good any blemishes.
This finish is for surfaces that are permanently exposed to view. The surface
produced by the formwork shall have smooth finish, free from board marks,
voids, honeycombing or other large blemishes. Any small blemishes shall be
carefully filled immediately after the removal of the formwork and other marked
imperfections such as fins or steps or joint marks shall be smoothed off and
made good.
This finish shall give an appearance of smooth, dense, well-compacted
concrete with no shutter marks, stain free and with no discolouration,
blemishes, arises, air holes, etc. Only lined or coated plywood with very tight
joints shall be used to achieve this finish. The panel size shall be uniform and
as large as practicable. Any minor blemishes that might occur shall be made
good by the Contractor.
Surfaces of precast elements, which are later to be in contact with in-situ
concrete, shall be roughened by air-water jetting, between the period of initial
and final set, to remove all laitance, cement slurry and fine aggregate. Coarse
aggregate is to be left exposed but undisturbed.
21.6 INTEGRAL CEMENT FINISH ON CONCRETE FLOOR
In all cases where integral cement finish on a concrete floor has been specified,
the top layer of concrete shall be screeded off to proper level and tamped with
tamper having conical projections so that the aggregate shall be forced below
the surface. The surface shall be finished with a wooden float and a trowel with
pressure. The finish shall be continued till the concrete reaches its initial set.
No cement or cement mortar finish shall be provided on the surface. Where
specified, a floor hardener of appropriate thickness as approved by the
ENGINEER shall be supplied and used as recommended by the manufacturer.
22.0 REPAIR AND REPLACEMENT OF UNSATISFACTORY CONCRETE
22.1 Immediately after the shuttering is removed, all the defective areas such as
honeycombed surfaces, rough patches, etc. shall be brought to the notice of
ENGINEER who may permit patching of the defective areas or reject the
concrete work. ENGINEER’s decision on rejection of concrete work shall be
final.
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22.2 All through holes for shuttering shall be filled with cement mortar for full depth
and neatly plugged flush with surface.
22.3 Rejected concrete shall be removed and replaced by CONTRACTOR at no
additional cost to OWNER.
22.4 For patching of defective areas all loose materials shall be removed, and the
surface shall be prepared by cleaning by compressed air or water jetting.
22.5 Bonding between hardened and fresh concrete shall be done either by placing
cement mortar or by applying epoxy. The decision of the ENGINEER as to be
the method of repairs to be adopted shall be final and binding on the
CONTRACTOR and no extra claim shall be entertained on this account. The
surface shall be saturated with water for 24 hours before patching is done with
1:5 cement sand mortar. The use of epoxy for bonding fresh concrete shall be
carried out as directed by ENGINEER.
22.6 CONTRACTOR shall submit a method statement for such repairs to
ENGINEER for approval.
23.0 VACUUM DEWATERING OF SLABS
23.1 Where specified floor slabs, either on grade or suspended, shall be finished by
vacuum dewatering including all operations such as poker vibration, surface
vibration, vacuum processing, floating and trowelling as per equipment
manufacturer’s recommendation. The equipment to be used shall be subject to
ENGINEER’S approval.
24.0 HOT WEATHER REQUIREMENT
24.1 Concreting during hot weather shall be carried out as per IS: 7861 (Part I).
24.2 Adequate provisions shall be made to lower concrete temperatures, which shall
not exceed 400 C at the time of placement of fresh concrete.
24.3 Where directed by ENGINEER, CONTRACTOR shall spray non-wax based
curing compound on unformed concrete surface at no extra costs.
25.0 COLD WEATHER REQUIRMENTS
25.1 Concreting during cold weather shall be carried out as per IS: 7861 (Part 2).
25.2 The ambient temperature during placement and up to final set shall not fall
below 50 C. Approved anti-freeze/ accelerating additive shall be used where
directed.
25.3 For major and large-scale concreting works the temperature of concrete at
times of mixing and placing, the thermal conductivity of the formwork and its
insulation and stripping period shall be closely monitored.
26.0 LIQUID RETAINING STRUCTURES
26.1 The CONTRACTOR shall take special care for concrete of liquid retaining
structures, underground structures and those other specifically called for to
guarantee the finish and water tightness.
26.2 The minimum level of surface finish for liquid retaining structures shall be of
smooth type. All such structures shall be hydro-tested.
26.3 The CONTRACTOR shall include in his price hydro-testing of structure, all
arrangements for testing such as temporary bulk heads, pressure gauges,
pumps, pipe lines, etc.
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26.4 Any temporary arrangements that may have to be made to ensure stability of
the structures shall also be considered to have been considered while quoting
the rates.
26.5 Any leakage/ sweating that may occur during the hydro-test or subsequently
during the defect liability period or the period for which the structure is
guaranteed shall be effectively stopped either by cement/ epoxy pressure
grouting, guniting or such other method as may be approved by the
ENGINEER. All such rectification shall be done by the CONTRACTOR to the
entire satisfaction of the OWNER/ ENGINEER at no extra cost to the OWNER.
27.0 HYDRO TESTING CONCRETE STRUCTURES
27.1 Hydrostatic test for water tightness shall be done at full storage level or soffit of
cover slab, as may be directed by ENGINEER, as described below:
27.1.1 In case of structures whose external faces are exposed, such as elevated
tanks, the requirements of the test shall be deemed to be satisfied if the external
faces show no sign of leakage or sweating and remain completely dry during
the period of observation of seven days after allowing a seven-day period for
absorption after filling with water.
27.1.2 In the case of structures whose external faces are submerged and are not
accessible for inspection, such as underground tanks, the structures shall be
filled with water and after the expiry of seven days after the filling, the level of
the surface of the water shall be recorded. The level of water shall be recorded
again at subsequent intervals of 24 hours over period of seven days. Backfilling
shall be withheld till the tanks are tested. The total drop in surface level over a
period for seven days shall be taken as an indication of the water tightness of
the structure. The ENGINEER shall decide on the actual permissible nature of
this drop in the surface level, considering whether the structures are open or
closed and the corresponding effect it has on evaporation losses. Unless
specified otherwise, a structure whose top is covered shall be deemed to be
water tight if the total drop in the surface level over a period of seven days does
not exceed 40 mm.
27.1.3 Each compartment/ segment of the structure shall be tested individually and
then all together.
27.2 For structures such as pipes, tunnels, etc. the hydrostatic test shall be carried
out by filling with water, after curing as specified, and subjecting to the specified
test pressure for specified period. If during this period the loss of water does
not exceed the equivalent of the specified rate, the structure shall be
considered to have successfully passed the test.
28.0 OPTIONAL TESTS
28.1 If ENGINEER feels that the materials i.e. cement, sand, coarse aggregates,
reinforcement and water are not in accordance with the specifications or if
specified concrete strengths are not obtained, he may order tests to be carried
out on these materials in laboratory, to be approved by the ENGINEER, as per
relevant IS Codes. OWNER shall pay only for the testing of material supplied
by the OWNER, otherwise CONTRACTOR shall have to pay for the tests.
Transporting of all material to the laboratory shall however be done by the
CONTRACTOR at no extra cost to OWNER.
28.2 In the event of any work being suspected of faulty material or workmanship
requiring its removal or if the works cubes do not give the stipulated strength,
ENGINEER reserves the right to order the CONTRACTOR to take out cores
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as per relevant IS specifications. All these tests shall be carried out by
CONTRACTOR at no extra cost to the OWNER. Alternately ENGINEER also
reserves the right to ask the CONTRACTOR to dismantle and re-do such
unacceptable work at the cost of CONTRACTOR.
28.3 If the structure is certified by ENGINEER as having failed, the cost of the test
and subsequent dismantling/ reconstruction shall be borne by CONTRACTOR.
28.4 The quoted unit rates/ prices of concrete shall deem to provide for all tests
mentioned above.
29.0 In case of doubt regarding the grade of concrete used, either due to poor
workmanship or based on cube strength results, Non-Destructive Tests (NDT)
shall be carried out to ascertain the strength of the concrete as per the technical
specification attached in the tender document.
30.0 QUALITY CONTROL
30.1 CONTRACTOR shall adopt the Quality Control format provided by the
ENGINEER. A copy of formats shall be furnished to CONTRACTOR by
ENGINEER/ OWNER after the contract is awarded.
30.2 Alternatively, if CONTRACTOR has his own QC formats he may adopt them
subjected to such modifications considered necessary by ENGINEER.
30.3 In either case CONTRACTOR shall submit his detailed Quality Assurance Plan
along with the bid. This would be reviewed, appropriately modified and
approved by CONSULTANT/ ENGINEER after the award of contract.
31.0 INSPECTION
31.1 All materials, workmanship and finished construction shall be subject to
continuous inspection and approval of ENGINEER. Materials rejected by
ENGINEER shall be expressly removed from site within 3 working days and
shall be replaced by CONTRACTOR immediately at no extra cost to OWNER.
32.0 CLEAN-UP
32.1 Upon the completion of concrete work, all forms, equipment, construction tools,
protective coverings and any debris, scraps of wood, etc. resulting from the
work shall be removed and the premises left clean.
33.0 ACCEPTANCE CRITERIA DURING CONSTRCUTION STAGE AND
HARDENED STATE
33.1 Any concrete work shall satisfy the requirements given below individually and
collectively for it to be acceptable.
(a) properties of constituent materials;
(b) characteristic compressive strength;
(c) specified mix proportions;
(d) minimum cement content;
(e) maximum free-water/cement ratio;
(f) workability;
(g) temperature of fresh concrete, if specified.;
(h) density of fully compacted concrete, if specified;
(i) cover to embedded steel;
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(k) tolerances in dimensions;
(l) tolerances in levels;
(m) surface finishes;
33.2 ENGINEER’s decision as to the acceptability or otherwise of any concrete work
shall be final and binding on the CONTRACTOR.
33.3 For work not accepted, ENGINEER may review and decide whether remedial
measures are feasible to render the work acceptable. ENGINEER shall in that
case direct the CONTRACTOR to undertake the remedial measures. These
shall be expeditiously and effectively implemented by CONTRACTOR. Nothing
extra shall become payable to CONTRACTOR by OWNER for executing
remedial measures.
34.0 MODE OF MEASUREMENT AND PAYMENT
34.1 The unit rate for concrete work under various categories shall be all inclusive
and no claims for extra payment because of such items and leaving holes,
embedding inserts, etc. shall be entertained unless separately provided for in
the Schedule of Quantities. No extra claim shall also be entertained due to
change in the number, position and/ or dimensions of holes, slots or openings,
sleeves, inserts or on account of any increased lift, lead of scaffolding, etc. All
these factors shall be taken into consideration while quoting the unit rates.
Unless provided for in the Schedule of Quantities the rates shall also include
fixing inserts in all concrete work, whenever required.
34.2 Payments for concrete will be made based on unit rates quoted for the
respective items in the Schedule of Quantities. No deduction in the concrete
quantity will be made for reinforcements, inserts, etc. and opening less than
0.100 sqm, in areas where concrete is measured in sqm and 0.010 cum where
concrete is measured in cubic metres. Where no such deduction for concrete
is made, payment for shuttering work provided for such holes, pockets, etc. will
not be made. Similarly, the unit rates for concrete work shall be inclusive or
exclusive of shuttering as provided for in the Schedule of Quantities.
34.3 Payment for beams will be made for the quantity based on the depth being
reckoned from the underside of the slabs and length measured as the clear
distance between supports. Payment for columns shall be made for the quantity
based on height reckoned up to the underside of slabs.
34.4 The unit rate for precast concrete members shall include formwork, mouldings,
finishing, hoisting and setting in position including setting mortar, provision of
lifting arrangement, etc. complete. Reinforcement and inserts shall be
measured and paid for separately under respective item rates.
34.5 Only the actual quantity of steel embedded in concrete including laps as shown
on drawings or as approved by ENGINEER shall be measured and paid for,
irrespective of the level or height at which the work is done. The unit rate for
reinforcement shall include all wastage, binding wires, chairs, spacer bars, etc.
for which no separate payment shall be made.
34.6 Where the formwork is paid for separately, it shall be very clearly understood
that payment for formwork is inclusive of formwork, shuttering, shoring,
propping, scaffolding, de-shuttering, etc. complete. Only the net area of
concrete formed (shuttered) shall be measured for payment.
34.7 Where reinforcement is supplied by OWNER, the quantity of chairs and spacer
bars shall be measured for accounting wastage only.
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SPEC. NO.
SHEET 39 OF 40
ALLIED WORKS
34.8 Cost of Admixtures shall be deemed to be included in the rates and no separate
payment shall be made.
ISSUE
R11

SPEC. NO.
SHEET 40 OF 40
ALLIED WORKS
CONCRETE POUR CARD
(a) CLIENT: DATE: POUR NO.
(b) PROJECT:
STRUCTURE:
(c) CONTRACTOR:
(d) MAX AGGREGATE SIZE mm SLUMP: mm
(e) DRG. NO.
(f) START/ COMPLETION TIME:
(g) CONCRETE GRADE QUANTITY: M / M3 MIXING TIME:
CONTRACTOR’s
SR. ENGINEER’s
ITEM REP. REMARKS
NO. SIGNATURE
SIGNATURE
1. CENTERLINES CHECKED
2. FORMWORK AND STAGING CHECKED
BEFORE CONCRETING
3. REINFORCEMENT CHECKED
4. COVER TO REINFORCEMENT CHECKED
VERIFIED TEST CERTIFICATE FOR
5. YES/ NO YES/ NO
CEMENT/ STEEL
ADEQUENCY OF MATERIALS/
6. YES/ NO YES/ NO
EQUIPMENT FOR POUR
EMBEDED PARTS CIVIL
CHECKED MECHANICAL
7.
(LOCATION AND
PLUMB) ELECTRICAL
POUR AUTHORISED SITE ENGINEER
SOFFIT(S) AND POUR TOP(T) LEVELS S(B) T(B)
CHECKED BEFORE (B) AND AFTER (A) FORM S(A) T(A)
8. REMOVAL (ONLY OF BEAMS OF OVER 10 M
SPAN AND IMPORTANT STRUCTURES LIKE
TG, ETC.)
CONSTRUCTION JOINT LOCATION AND TIME
9.
(IF NOT AS PER DRAWING)
10. CEMENT CONSUMPTION IN KG
NUMBER OF CUBES AND IDENTIFICATION
11.
MARK
12. TEST CUBE RESULTS (7 DAYS/ 28 DAYS) / / /
VERY GOOD/ GOOD/ FAIR/
13. CONCRETE CONDITION ON FORM REMOVAL
POOR
SITE-IN-CHARGE
NOTES:
1. EACH ITEM TO BE CHECKED AND SIGNED BY THE RESPECTIVE ENGINEERS.
2. ITEMS 8 TO 13 (BOTH INCLUSIVE) TO BE FILLED BY ONLY TCE ENGINEER.
3. EACH POUR TO HAVE SEPARATE CARDS, IN TRIPILCATE ONE EACH FOR CLIENT, TCE AND
SITE OFFICE.
UNDER REMARKS INDICATE DEVIATIONS FROM DRAWINGS AND SPECIFICATIONS,
CONGESTION IN REINFORCEMENT, IF ANY, UNUSUAL OCCURENCES, SUCH AS FAILURE OF
EQUIPMENT, SINKING OF SUPPORTS/ PROPS, HEAVY RAINS AFFECTING CONCRETEING,
POOR COMPACTION, IMPROPER CURING, OTHER DEFICIENCIES, OBSERVATIONS, ETC.
ISSUE
R11

TATA CONSULTING ENGINEERS LIMITED SECTION:
SPEC. NO. WRITE-UP
TCE.M4-403-01-1
SPECIFICATION FOR GROUTING SHEET 1 OF 6
1.0 SCOPE
The works covered under this specification consists of supplying all

materials; furnishing all equipment, labour etc.; performing all operations; for
placing grouts at locations such as under column base plates, anchor bolt
pockets, under machine or equipment bases etc. The works shall be carried
out in conjunction with other contractors/vendors who are responsible for
erection of their structures and equipment and maintaining the levels,
alignments etc. of their bases.
2.0 MATERIALS
2.1 PREBLENDED GROUTS:

Pre-blended grouts shall be conforming to ACI:351.1-12. Qualification
requirements of pre-blended grouts shall be based on the results of tests
performed in accordance with ASTM C1090-10 and ASTM C827/C827M-08
in combination with the performance evaluation and flow evaluation tests as
per ACI: 531.1-12.
2.2 FIELD PROPORTIONED GROUT

This grout shall be prepared at site and strength of grout shall be two grades
higher than the concrete grade over which it is placed. Field grout shall be
prepared using cement, fine aggregates, and admixtures and so
proportioned to get the desired strength. Field grout shall meet the
requirements of ACI:351-1-12.
2.2.1 cement
Cement shall be ordinary Portland cement conforming to IS:8112/ ASTM
C150.
2.2.2 Aggregates
Sand shall be clean and well graded conforming to IS383. For fluid mix
grout, sand shall conform to zone-4 grade. Course aggregates wherever
used shall also conform to IS 383/ ASTM C33/ C144-11.
2.2.3 Water used for mixing of grout shall be clean and free from oils, acids,
alkalis, organics and other deleterious materials and conforming to the
requirements of IS:456
2.2.4 Admixtures
Admixtures that reduce settlement shrinkage and provide expansion in the

plastic state shall be used in all field proportioned grout mixtures. Chemical
The contents of this document are proprietary and confidential to Tata Consulting Engineers Limited (TCE) and the ISSUE
disclosure of the contents to anyone outside TCE is strictly prohibited except with the prior written consent from TCE R5

SPEC. NO. WRITE-UP
TCE.M4-403-01-1
admixtures, such as high-range water reducing admixtures, water reducers,

and air entrianing admixtures can also be used.
2.5 TYPE OF GROUTS
There are three types of grouts to be used.

i) Dry pack grouts
ii) Non-shrink cementitious grouts
iii) Non-shrink epoxy grouts. (The type of grout to be used shall be as
specified in the drawings or as advised by Engineer or as directed by
the equipment supplier)
2.6 DRY PACK GROUTS
This is a field proportioned grout and shall be prepared by mixing of cement

and sand. The proportion of grout shall be one part of Portland cement to 2
parts of sand unless otherwise specified. Quantity of water shall be such
that it is just enough for compaction and hydration and shall have the
consistency of damp sand. If the thickness of grout is more than 40mm
cement aggregates grout shall be used. Mix proportion of cement sand and
coarse aggregates shall be 1:1.25:3 by weight and coarse aggregates size
shall be 10mm downgraded. Dry pack grout requires almost unobstructed
space and must be installed by skilled workers. Surface contact achievable
with this grout will be 75 ot 80% under baseplates. Lightly loaded structures
column bases can be provided with this type of grout.
2.7 NON-SHRINK CEMENTITIOUS GROUTS
These shall be a pre-blended (pre-proportioned) product, obtained from
approved manufacturers, containing a mixture of aggregate, cement and
admixtures; pre-blended and pre-packaged requiring only the addition of
water at site. Unless mentioned otherwise, it shall be used below all
structural base plates and associated anchor bolt pockets. It can also be
used below all static and rotating equipment bases having no or low impact
loads unless specified by the equipment supplier. It shall not be used in
areas where the grouts are subjected to corrosive atmosphere and chemical
attacks. The material shall be chloride free and must not contain expansive
cements or metallic particles such as aluminium powder or iron fillings.
2.8 NON-SHRINK EPOXY GROUTS
These are two components epoxy bonding systems mixed with oven dry
aggregate and other proprietary materials. It shall be obtained from
approved manufacturers. The components shall be mixed in complete units
in accordance with manufacturer’s recommendations. If not specifically
mentioned, it shall be used in areas where the grouts are subjected to

SPEC. NO. WRITE-UP
TCE.M4-403-01-1
corrosive atmosphere or aggressive chemicals and/or shock or heavy

impact loads below equipment bases, such as reciprocating machines,
crushers, crane rails etc. Where epoxy grouts are subjected to temperature
more than 50o C, manufacturer’s advice shall be sought before its use, as its
stiffness and strength get affected under high temperature.
3.0 SURFACE PREPARATION
3.1 Concrete surfaces to be grouted shall be thoroughly cleaned by compressed

air and all loose materials from the surface shall be removed.
3.2 Anchor bolts, anchor bolt holes and the bottom of equipment and column
base plates shall be cleaned of all oil, grease, dirt and loose material.
3.3 The hardened concrete surfaces on which the cementitious grouts are to be
placed shall be saturated with water. All standing water shall be removed
from the concrete surface as well as from anchor bolt holes, just prior to
grouting. However, surface shall be absolutely dry before placing epoxy
grouts.
4.0 INSTALLATION
4.1 Ready mixed grouts shall be mixed in the manner and in accordance with
manufacturer’s recommendations and shall be used in the form of liquid/
fluid. In case of field proportioned mix it shall be prepared, mixed and placed
in accordance to ACI:351-1-12. Consistency of grout shall be such so that it
can maintain its flowability within the gap provided below the base plates,
during its entire period of placement. Grouts shall be placed from one end to
the other. Grouting, once started, shall be finished quickly and continuously
to prevent segregation, bleeding and starting of initial set. No water or
solvent shall be added to change the consistency, if the grout stiffens during
placement. The stiffened grouts along with other grout, in place but not
completed, shall be removed.
4.2 The bases of structures and equipment are levelled and aligned by other
vendors by using shims. Shims shall be positioned at the edges of bases to
permit easy subsequent removal.. In case of fliud /plastic mix, grout of
suitable mix shall be poured immediately after preparation into the
pockets/blockouts/bolt holes/space between the base & concrete either from
sides or through holes made in bases by using special equipment for
pressure grouting. dry pack grouts, if used, shall be placed by firmly
pressurizing or ramming into the place against fixed supports or rodding.

SPEC. NO. WRITE-UP
TCE.M4-403-01-1
Extreme care shall be taken to see that alignment and levels of bases are
not disturbed during grouting.
It shall be ensured by rodding and tapping of bolts that the blackouts are
completely filled with grout without leaving voids
4.3 The grouts shall be prepared only to the extent it can be used within the
specific pot life by the manufacturer. Any leftover grout or grouts not
consumed within the pot life time shall not be used and shall be discarded.
The shelf life of the grout shall also be checked before they are used.
Grouts having expired date shall not be used under any circumstances.
4.4 The cementitious grouts shall be cut back at an angle of 45degrees to

horizontal or vertical, as shown in the drawing, after the grout has reached
its initial set. Grouting, once started, shall be done quickly and continuously
to prevent segregation, bleeding and break down of initial set. Grout shall be
worked from one side of one end to the other to prevent entrapment of air.
To distribute the grout and to ensure more complete contact between base
plate and foundation and to help release of entrapped air, link chains or
doubled over flexible steel strapping’s may be used to work the grout into
place.
4.5 Forms and shims shall not be removed and the anchor bolts shall not be
tightened for at least twenty four hours after placing the grout. After removal
of forms and peripheral shims, area occupied by shims shall be filled and
the area between the base and the edge of the foundation shall be finished
smooth to allow drainage away from the base. Interconnecting piping shall
not be attached to the machinery before anchor bolts are tightened. It is
desirable to make these connections at least after a minimum of seven
days from the date of grouting. During this period, the grout shall be
properly cured.
4.6 Grout shall be cured for a period of at least 7 days commencing 24 hours
after the completion of grouting. The curing shall be done by covering the
surfaces with wet gunny bags and flooding unless otherwise
specified/recommended by grout manufacturer.
5.0 INSPECTION
5.1 All materials, workmanship and finished construction shall be subject to the
continuous inspection and approval of ENGINEER.
5.2 All materials supplied by CONTRACTOR and all works or construction

performed by CONTRACTOR and rejected - as not in conformity with the

SPEC. NO. WRITE-UP
TCE.M4-403-01-1
specifications and drawings - shall be immediately replaced at no additional

expense to the OWNER.
5.3 Preliminary approvals of any materials or phase of work shall in no way

relieve the CONTRACTOR from the responsibility of supplying grouting
materials and or producing finished grout in accordance with the
specifications and drawings.
5.4 All grouting shall be protected against damage until final acceptance by
OWNER or his representative.
5.5 Upon the completion of grouting work, all forms, equipment, construction
tools, protective coverings and any debris shall be removed from the area as
6.0 GENERAL
6.1 The thickness of standard dry pack grouts shall be minimum 75mm.
However,thickness of flow-able grout can be anywhere between 20 to 50mm
except in case of equipment bases where grout thickness shall be as per
equipment supplier’s recommendation.
6.2 Generally, the Crushing strength of grout shall be one grade higher than the
base concrete on which the grout is placed. However in case of large
equipment foundations like TG deck, wind mill pedestals, grout strength
shall be arrived based on actual bearing stress due to external loads via-a-
vis allowable bearing pressure on concrete unless otherwise specified by
the equipment supplier. Minimum crushing strength shall be 30N/mm2,
unless otherwise specified.
6.3 Full contact area between the grout and baseplate shall be ensured..
6.4 All materials shall be delivered to site in original unopened packages, clearly
labelled with the manufacturer’s identification and printed instructions. The
contractor must submit the manufacturer’s certified test data on the grout’s
constituents, 24 hour compressive strength and its flowability, from
approved test laboratory, prior to placement of order. Manufacturers shall
also give warranty saying that the non-shrink grout supplied shall never go
below its initial placement volume.
6.5 Forms around base plates shall be reasonably tight to prevent leakage of
the grout. When the base is to be flow grouted, forms shall be built and
securely anchored outside the base plate so as to completely confine and
withstand the pressure of liquid grout under working and rodding condition
without leaking and high enough to ensure the grout is in contact with the

SPEC. NO. WRITE-UP
TCE.M4-403-01-1
underside of the base plate, and provide a head of minimum 100 mm above
the underside of the base plate. Provisions of grout holes in base plates,
rodding, arrangements shall be checked prior to commencement of grouting.
6.6 Adequate clearances shall be provided between forms and base plate to
permit grout to be worked properly into place.
6.7 Grouting through holes in base plates shall be by pressure grouting. The
pressure to be used for grouting shall be as directed by the ENGINEER.
7.0 MODE OF PAYMENT
7.1 Quantity of grout used will be calculated on the basis of dimensions

measured accurately but not exceeding the quantity as per the drawing.
Payments will be made per cubic meter of grout as per unit indicated in
schedule of quantities.
7.2 No deduction shall be made for shims, bolts, shear keys and other such
embedment.
END

SPEC. NO. TATA CONSULTING ENGINEERS LIMITED SECTION: WRITE UP
TCE.M4-405-01 SUPPLY AND FABRICATION OF STRUCTURAL STEEL SHEET 1 OF 28
1.0 SCOPE
1.1 This specification covers the general requirements for supply of all structural
steel items where specified, fabrication, inspection and testing of all fabricated
structural steel items. Volume III/SECTION C covers the specific requirements
for the project. The two parts are complementary and are to be read together
for a correct interpretation of the provisions of this specification. Where
requirements of the two parts conflict; those of Volume III/SECTION C shall
govern.
1.2 This specification also covers design of all connections and substituted
members, preparation of all shop fabrication drawings, inspection of fabricated
items.
1.3 The scope of work also includes but is not limited to supply (if the fabrication
shop is not within plant site), proper stacking and storage of fabricated
materials. All the works shall be carried as per approved QA procedures.
2.0 APPLICABLE CODES STANDARDS AND SPECIFICATIONS
The pertinent clauses of the following Indian Codes, Standards and

Specification shall apply to the material and workmanship covered by this
specification. In the event of the conflict of certain requirements between this
specification and the codes referred herein, this specification shall govern.
The codes and standards mentioned herein shall be latest as on the day of
award of contract of the works unless otherwise specified. Contractor shall be
responsible to inform to the Consultant/ Owner in case of any revisions/re-
affirm/amendment in the relevant codes and standards after the date of award
of contract within 30 days of the issue of such revision/re-affirm/amendment of
the code/ standard. Consultant/ Owner may approve use of the earlier code/
standard if the revisions do not materially affect the statutory requirements of
the project or does not impact safety practices. Any cost impact arising out of
such revisions shall be mutually agreed.
It is not the intent to specify herein all the codes and standards required for the
satisfactory completion of work. The list of codes and standards indicates
certain primary codes and standards and not all the codes required for the work
under the contract. It is understood that all the pertinent codes and standards
shall form the part of this specification whether explicitly indicated or not.
FILE NAME: M4-405-01-Rev-R9.docx

herewith. In consideration of receipt of this document; unless agreed to in contrary in the Contract; the recipient agrees to maintain such information in confidence and to not reproduce or otherwise disclose this
from Tata Consulting Engineers Limited, or becomes publicly known through no fault of recipient, or Tata Consulting Engineers Limited, or is received without obligation of confidentiality from a third party owing no
subsequently communicated in writing) or in writing or otherwise given under any and all previous version/s. ISSUE
R9

IS 800: 2007 General Construction in Steel –Code of Practice

(Reaffirmed 2017)
IS803:1976 Code of Practice for Design, Fabrication and

(Reaffirmed 2017) Erection of Vertical Mild Steel Cylindrical Welded
Oil Storage Tanks.
IS 806:1968 Code of Practice for Use of Steel Tubes in

(Reaffirmed 2017) General Building Construction
IS 808: 1989 Dimensions for Hot Rolled Steel Beam, Column,

(Reaffirmed 2014) Channel and Angle Sections
IS 813:1986 Scheme of symbols for welding

(Reaffirmed 2013)
IS 814: 2004 Covered Electrodes for Manual Metal Arc Welding

(Reaffirmed 2014) of Carbon and Carbon Manganese Steel-
Specification
IS 816:1969 Code of Practice for use of Metal Arc Welding for

(Reaffirmed 2019) General construction in Mild Steel
IS 822:1970 Code of Procedure for Inspection of Welds

(Reaffirmed 2019)
IS 1024:1999 Code of practice for use of welding in bridges and

(Reaffirmed 2019) structures subjected to dynamic loading
IS 1161: 2014 Steel Tubes for structural purposes-Specification

(Reaffirmed 2019)
IS 1182: 1983 Recommended Practice for Radiographic

(Reaffirmed 2020) examination of Fusion Welded Butt Joints in Steel
Plates.
IS 1239:2004 Steel Tubes, Tubular and Other Wrought Steel

(Reaffirmed 2019) Fittings-Specification-Part 1: Steel Tubes
IS 1239: 2011 Mild steel tubes, tubular and other wrought steel
(Reaffirmed 2016) fittings-Part 2: Mild steel tubular and other
wrought steel pipe fittings
IS 1363:2019 Hexagon Head Bolts, Screws and Nuts of Product

Grade ‘C’
Part 1: Hexagon Head Bolts (Size range M5 to
M64)
IS 1363:2018 Hexagon Head Bolts, Screws and Nuts of Product

Grade ‘C’
ISSUE
R9

Part 2: Hexagon Head Screws (Size range M5 to

M64)
IS 1363:2018
Part 3: Hexagon Nuts (Size range M5 to M64)
IS 1367:2017 Technical Supply Conditions for Threaded
Fasteners (All Parts)
Part-3: Technical supply conditions for threaded
steel fasteners: Part 3: Mechanical properties of
fasteners made of carbon steel and bolts, screws
and nuts.
IS 1395:1982 Low and medium alloy steel covered electrodes

(Reaffirmed 2019) for manual metal arc welding
IS 1852:1985 Rolling and Cutting Tolerances for Hot Rolled

(Reaffirmed 2017) Steel Products (4th Rev)
IS 2062:2011 Hot Rolled low, medium and High tensile

(Reaffirmed 2016) structural steel
IS 2595:2008 Code of Practice for Radiographic Testing

(Reaffirmed 2020)
IS 3502:2009 Steel Chequered Plates-Specification.

(Reaffirmed 2015)
IS 3600:1985 Method of Testing Fusion Welded Joints and

(Reaffirmed 2019) Weld metal in Steel: Part 1 Cruciform fillet weld
tensile test.
(Reaffirmed 2019) Weld metal in Steel: Part 2 Beam Impact (Charpy
V-notch) test.

Weld metal in Steel:
Destructive Tests on Welds in Metallic Materials -
part 3: Transverse Tensile Test.

(Reaffirmed 2016) Weld metal in Steel:
Part 4 Longitudinal Tensile Test on Cylindrical
Weld Metal test pieces on Butt welds.

Part 5 Transverse Root and Face Bend Test on
Butt Welds.

Part 6 Transverse Side Bend test on Butt Welds. ISSUE
R9

Method of Testing Fusion Welded Joints and

IS 3600:1985 Weld metal in Steel:
(Reaffirmed 2019) Part 7 Longitudinal root and Face Bend Test on
Butt Welds.

Part 8 Nick Break Test and Fillet Weld Fracture
Test.
Method of Testing Fusion Welded Joints and
IS 3600:1985 Weld metal in Steel:
(Reaffirmed 2019) Part 9 Macro and Micro Examination.
IS 3658:1999 Code of Practice for Liquid Penetrate Flaw

(Reaffirmed 2020) Detection
IS 3757:1985 Specification for High Strength Structural Bolts

(Reaffirmed 2019)
IS 7318- 1974 Approval Test for Welders when welding

(Reaffirmed 2019) procedure approval is not required Part 1: Fusion
welding of steel
IS 817 - 1966 Code of practice for training and testing of metal

(Reaffirmed 2019) arc welding.
IS 4000:1992 Code of Practice for High strength bolts in Steel

(Reaffirmed 2017) Structures
IS 4260:2004 Recommended practice for ultrasonic testing of

(Reaffirmed 2015) butt welds in ferritic steel.
IS 4353:1995 Submerged arc welding of mild steel and low alloy

(Reaffirmed 2016) steels –Recommendations
IS 5334:2014 Magnetic Particle Flaw Detection of Welds-Code

(Reaffirmed 2020) of Practice
IS 6639:1972 Specification for Hexagon Bolts for Steel

(Reaffirmed 2015) structures
IS 7215:1974 Tolerances for Fabrication of Steel Structures.

(Reaffirmed 2016)
IS 9595:1996 Metal Arc Welding of Carbon and Carbon

(Reaffirmed 2019) Manganese Steels-Recommendations
IS 12778:2004 Hot rolled parallel flanged section for beams,

(Reaffirmed 2014) columns
ISSUE
R9

SP:6(1):1964 Structural Steel Sections.

(Reaffirmed 2003)
AWS D1.1:2015 Structural Welding Code: Steel

Jindal steel Catalogue
3.0 REGULATORY REQUIREMENTS:
The work covered in this specification, shall comply with all relevant
government and local laws, regulations and standards. For subjects not
covered by regulations, codes, standards or specifications, the materials and
construction shall be based on good engineering practice, subject to approval
by OWNER.
4.0 STEEL MATERIALS
Structural steel will be either supplied by OWNER or CONTRACTOR.

Depending upon the scope of supply, the following clauses shall be applicable
respectively. Steel materials shall comply with the specifications laid down
under clause 2.0 and/or as called for on the design drawings. All materials used
shall be new, unused and free from defects
4.1 STEEL SUPPLY – BY OWNER
4.1.1. The CONTRACTOR shall use steel supplied by the OWNER judiciously and to
the best advantage so as to minimize splicing and wastage. All steel materials
remaining after completion of the work, whether in the form of balance pieces
or unutilized prime steel, shall be returned to the OWNER’s stores by the
CONTRACTOR at his own cost. Reconciliation of steel supplied and wastage
will be as specified in the Contract.
4.1.2. Structural steel materials will be issued in sizes as received from manufacturer
/ suppliers within the project area at the departmental stores free of cost or at
the rates specified in the Contract. The CONTRACTOR shall make necessary
arrangements for carriage, loading, unloading of all materials to work site at his
own cost within the rates quoted and agreed for the job.
4.1.3. OWNER shall furnish the mill / manufacturer’s test reports, along with the
materials and satisfactorily demonstrate the specific grade and quality.
4.1.4. All materials required for the work shall be correlated with manufactures test
certificates. In the absence of test certificates, CONTRACTOR shall test
materials through reputed laboratory approved by ENGINEER for establishing
quality, at OWNER’s cost and as directed by the ENGINEER. ISSUE
R9

4.1.5. On receiving each consignment of steel from the OWNER the CONTRACTOR
shall acknowledge in writing the receipt thereof giving full particulars of
sections, sizes, quantities, grade and quality. Should there be any damage or
distortion of the materials in transit, the CONTRACTOR shall immediately
report the matter to the ENGINEER in writing.
4.1.6. The CONTRACTOR shall take proper care of the steel supplied by the OWNER
and protect them from weathering and damage. Any such materials rendered
unserviceable or damaged while in the CONTRACTOR’s custody shall be
replaced by the CONTRACTOR at his own cost as determined by the
ENGINEER.
4.1.7. In cases where after receipt of visibly good tested quality steel from the
OWNER, defects such as laminations, seams, tears, fins etc., are discovered
during fabrication, the work on such sections shall be stopped immediately and
the matter shall be brought to the notice of OWNER who shall arrange for
replacing the affected sections, if necessary.
4.1.8. CONTRACTOR shall use the materials as issued by the OWNER to fabricate
the structures as required. No extra claim on account of extra welding and / or
cutting due to non-conformity of sizes with the drawings issued will be
entertained.
4.1.9. Steel required for the work will be issued to the CONTRACTOR on the basis of
approved fabrication drawings and drawings released for construction.
4.1.10. Steel will be issued to the CONTRACTOR on the basis of standard sectional
weights and measured lengths rounded off to nearest 5mm with Unit weights
given in BIS 808. For sections and weights not covered in IS: 808, unit weights
as given by the manufacturers shall be considered for calculation of weight.
The same unit weight shall be used in the BOM included in fabrication
drawings.
4.2. STEEL SUPPLY – BY CONTRACTOR.
4.2.1 All steel and other material shall be procured and supplied by the
CONTRACTOR, from reputed manufacturers as mentioned in tender
document. Steel proposed to be procured from other manufacturers shall have
prior approval from the OWNER before placement of procurement order.
However, OWNER reserves the right to accept or reject material from other
manufacturers. Materials from re-rollers will not be accepted. Steel procured
shall conform to the applicable codes & standards mentioned in clause 2.0.
4.2.2 CONTRACTOR shall use materials for fabrication as specified in the approved
ISSUE
drawings. All materials supplied by the CONTRACTOR shall be in sound R9

condition, of recent manufacture, free from defects such as mill scales, slag
intrusions, laminations, pitting, flakes, rust etc. and be of full weight and
thickness as specified.
4.2.3 CONTRACTOR shall furnish the mill / manufacturer’s test reports, along with
the materials and satisfactorily demonstrate the specific grade and quality.
Material test certificate shall be in original.
4.2.4 All materials required for the work shall be correlated with manufactures test
certificates. In the absence of test certificates, CONTRACTOR shall test
materials through reputed laboratory approved by ENGINEER for establishing
quality, at CONTRACTOR’s cost and as directed by the ENGINEER.
4.2.5 Material supplied against each Test Certificates (TC) shall have identification
stamped or stencilled on them. All such identification markings shall be
authenticated by the inspection agency, which has inspected and approved
the material.
4.2.6 The CONTRACTOR shall furnish to the ENGINEER duplicate copies of all
purchase order copies covering the material ordered by him for the project
under reference and also test reports.
4.2.7 The OWNER/ ENGINEER shall have the right to test random samples to
prove authenticity of the test certificates produced by the CONTRACTOR at
OWNER’s cost. Any material found not meeting the required specification
would be rejected. The cost of testing, if material gets rejected shall also then
be borne by CONTRACTOR.
4.2.8 Whenever the CONTRACTOR desires to substitute structural members /

shapes, plates for the sizes shown on the drawings, for want of availability of
requisite materials, such substitutions shall be made only after authorization in
writing by the ENGINEER. ENGINEER may also direct that substitution be
made, when he considers such substitution to be necessary.
5.0 DRAWINGS.
5.1 ENGINEER’S DRAWINGS (OWNER’S DRAWING)
5.1.1 Engineer will issue to CONTRACTOR such drawings and data as specified in
Contract which may include, depending on Contract:
a) Preliminary Drawings and Data along with Tender / Enquiry.
b) Interface particulars with other Contracts and
c) Detailed engineering design drawings in OWNER’s Scope.
ISSUE
R9

5.1.2 Design drawings will be furnished to the CONTRACTOR unless working on 3D

model is agreed upon and all drawings so furnished shall form a part of this
specification. These design drawings prepared by the ENGINEER will show
layout, all the levels, forces on members where necessary, size and orientation
of each member, location/size of openings, typical and special connections, to
enable the CONTRACTOR to prepare drawings for fabrication and erection. It
shall be clearly understood that ENGINEER’s drawings are design drawings
and are not intended to show connection details, thickness of gussets, cuts,
notches, bends and other such details.
5.1.3 Drawings of structures and systems engineered by ENGINEER or Others will

be made available to CONTRACTOR, progressively before commencement of
respective parts of works correlating with actual progress of works ensuring
that there is no delay for want of drawings. CONTRACTOR shall intimate in
writing, his projected date of requirement of drawings. The Schedule of release
of drawings shall be mutually agreed to, based on project schedules, unless
such dates of drawing release are specified in Contract.
5.1.4 Engineer reserves the right to make changes; revisions to drawings, even after
release for preparation of shop drawings, to reflect additional data/details
received and updated requirements. Revisions to drawings and any new
drawings made to include additional work by the OWNER shall be considered
as part of this specification and contract without additional cost implication to
the OWNER. The OWNER shall not entertain any extra claims on this account.
5.1.5 In case of variations in drawings and specifications, the decision of the

ENGINEER shall be final. Should the CONTRACTOR find discrepancies in the
information furnished by the Engineer, he shall refer these to the ENGINEER
before proceeding with such work.
5.1.6 Unless otherwise specified, the drawings and specifications are intended to
include everything obviously requisite and necessary for proper and entire
completion of the work and shall be carried out accordingly for completeness
as required.
5.2 CONTRACTOR’S DRAWINGS (FABRICATION DRAWINGS)
5.2.1 Fabrication drawings shall be prepared by the CONTRACTOR or through an

agency approved by ENGINEER based on the ENGINEER’s Design drawing
“Released/ Good for Construction” and their subsequent revisions. Cost of
preparation of fabricated drawing shall be borne by the CONTRACTOR. When
the Design drawings are developed in the form of 3D structural model, the
Contractor is free to develop fabrication details on approved 3D model subject
to approval of the Owner without any implication to cost and time. and detail
drawings may be extracted in the form and format as per the requirement of
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the Owner. The tools of 3D model and drawings shall be as instructed by the R9

Owner. All the drawings for the entire work shall be prepared in metric units.
The drawings shall preferably be of one standard size and the details shown
there in shall be clear and legible. Drawings shall be prepared in computer
tools and the details shall be drawn to the minimum scale as specified under.
a) Marking Plan : 1:75

b) Joint Details : 1:5; 1:10; 1:15
c) Elevations : 1:20
5.2.2 CONTRACTOR shall not commence detailing unless ENGINEER’s design

drawings are officially released for preparation of shop drawings. The
CONTRACTOR shall be responsible for the correctness of all fabrication
drawings. Fabrication drawings shall be revised by the CONTRACTOR to
reflect all revisions in design drawings as and when such revisions are made
by the ENGINEER.
5.2.3 Key plan prepared by the CONTRACTOR shall indicate the fabrication /
erection marking of each member and a table showing the corresponding
fabrication drawing number where these members are detailed. Also, each
drawing prepared by CONTRACTOR shall indicate corresponding
ENGINEER’s design drawing number with revisions.
5.2.4 Each member shall be detailed separately unless members are identical in all
respects with no deviation whatsoever. Shop detail drawings shall show all
shearing, punching, drilling, bevel cutting, bending, and all welding in complete
detail. All connections and splices shall be designed and detailed by the
CONTRACTOR and clearly shown on the drawings. Bill of material shall show
number, size, length, weight and assembly work of each erection piece. Bill of
material for each drawing shall include fasteners/bolts, nuts, washers and
other accessories complete with specification, size, length, numbers, etc., for
each erection mark and proper identification for each joint. Bill of material shall
be prepared erection mark wise, showing weight of each component part and
total weight of each erection mark. All revisions after initial issue of a drawing
shall be clearly indicated with issue number and date of revision.
5.2.5 Each drawing prepared by the CONTRACTOR shall clearly indicate Names of
OWNER, ENGINEER, CONTRACTOR, Project Title, Title of drawing, Scale,
Notes, Details of revisions carried out etc. All titles, noting, markings and
writings on the drawing shall be in English and all dimensions shall be in metric
units. Before the commencement of preparation of fabrication drawings,
CONTRACTOR shall discuss with the ENGINEER any specific requirement to
be followed for fabrication drawing preparation.
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5.2.6 No detailed shop drawings will be accepted by the ENGINEER unless they are
complete and checked and approved by CONTRACTOR’s qualified Structural
ENGINEER and accompanied by an erection plan showing the location of all
pieces detailed.
5.2.7 CONTRACTOR shall check for erection clearance and ensure that detailing of
connections is carefully planned to obtain ease in erection of structures
including field-welded connection and bolting. Field connections/splices may
be welded or bolted type as specified in design drawings.
5.2.8 CONTRACTOR shall submit design calculations for major connection detail as
advised by the ENGINEER, splices proposed by him and also for any
substitution members desired by him and approved by the ENGINEER.
Fabrication drawings not accompanied by calculation for such connection
details/ splices are liable for rejection.
5.2.9 Each lot of drawings sent by CONTRACTOR for approval shall contain a limited
number of drawings and shall be in an order and manner which follows erection
sequence or as required by ENGINEER based on priorities allocated.
ENGINEER will return copy of CONTRACTOR's drawing marked with
ENGINEER’s approval/comments. CONTRACTOR shall furnish the
ENGINEER the required number of prints and soft copy of all approved
drawings for field use and record purpose.
5.2.10 In addition to standard engineering practice in detailing and provisions of IS

800:2007, the following special requirements shall be strictly followed while
detailing.
a) All butt welds shall be full penetration butt weld.
b) In the case of main columns fabricated out of plates, the weld connecting
flanges and web to the base plate shall preferably be double vee butt welds or
as indicated in fabrication/ connection drawing.
c) At column bases, wing plates shall be connected to the column flanges by full
strength single vee butt weld.
d) In the case of built up column sections, the thickness of the continuous fillet
weld between flanges and web shall be a minimum of ½ the web thickness and
this weld shall be calculated based on standard formula considering the shear
force as the full shear capacity of the web, unless a thicker size weld is specified
in the design drawings.
e) Shop splice location for flanges and web of built up columns/ girders shall be
staggered by at least 500 mm such that only one full strength butt weld exist in
one horizontal plane.
f) Where the thickness of plates changes, in the case of flange plates, outside
surface shall be kept flush. The thicker plate shall be chamfered to slope of 1
horizontal to 5 vertical so that at the location of weld; thickness of plate will be
same on either side of weld. In the case of webs at the location where the plate
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thickness changes, the plates will be kept symmetrical to the vertical axis: the R9

thicker plates shall be given a chamfer on both sides such that at the location
of butt welds, thickness of plate on either side will be equal.
g) Similarly, where the width of the flange plate changes, the wider plate shall be
tapered with a slope 1 horizontal to 5 vertical.
h) Site splicing may be by welding or by means of high tensile bolts.
i) In the case of built up framing beams, the weld between flange and web shall
be calculated based on standard formula considering the shear force as the full
shear capacity of the web. Continuous weld shall be provided keeping size of
weld uniform for the full length of girder. However, is no case the size of weld
shall be less than half the web thickness.
j) Weld between flanges and web both for column as well as beams, shall
preferably be made using automatic welding machines, with proper sequence
of welds to avoid warping. The processing of welding and the methodology
shall be got approved before welding is started.
k) Connection of bracings /tie beams to column shall follow the details given in
the design drawings. The maximum size of the weld shall be less than or equal
to the thickness of the rolled section at the location of connection.
l) Thickness of gusset plates if not specified on design drawings shall be at least
equal to the thickness of member connected and shall have adequate cross
section to transfer the force at the point. If the members are connected on either
side of gusset, thickness of gusset shall be more than sum of thickness of fillet
weld on either side of gusset. Layout of gusset plate shall be such that the
eccentricity between member c.g. and the c.g of connection gusset is a
minimum.
5.2.11 ENGINEER may review / approve some, all or none of the fabrication drawings
at his option. Wherever such review is carried out the same shall be restricted
to the following-
a) Review/ approval of the size of members, dimensions and general arrangement

but shall not constitute approval of the connections between members and
other details.
b) Correctness of overall dimensions, centre to centre distance, elevations.
Important / typical connection details (adequacy of number of bolts / weld length
for few connections only will be checked), working points for bracing members
and orientation and sizes / sections of members.
c) Sequence of erection in the light of project requirements.
d) Whether the fabrication drawings broadly conform to details shown on design
drawings and comply with technical specifications, general notes, any specific
notes made on design drawings and generally with the requirement of good
engineering practice.
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5.2.12 It shall be clearly noted by the CONTRACTOR that even where review is done
by the ENGINEER, the following shall be the sole responsibility of the
CONTRACTOR.
a) Provision for erection.
b) Marking of members.
c) Cutting Lengths of members
d) Matching of Joints and holes
e) Provision kept in the member for all other interconnected members
f) Bill of materials.
g) Gusset sizes.
h) Connections
5.2.13 Approval by ENGINEER of any of the fabrication drawings shall not relieve the
CONTRACTOR from the responsibility for correctness of engineering, design
of connections, workmanship, and fit of parts, details, material, errors or
omissions of any and all work shown thereon. ENGINEER’s approval shall not
invalidate any claim by OWNER for damages of any kind for incorrectly
detailed / fabricated steel.
5.2.14 On completion of fabrication and erection, the CONTRACTOR shall update

his fabrication drawings, incorporating all site changes and substitutions and
shall submit required sets of hard copies of such “as built “drawings to OWNER
for record purpose as indicated in the tender document. The CONTRACTOR
shall also furnish soft copies of all final approved CONTRACTOR’s drawings
in the form of CDs. When detailing will be done on 3D model then the final “as
built” 3D model shall be submitted to the Owner.
5.2.15 Time consumed by the CONTRACTOR in securing approval of drawings shall

not be added to the time allowed for completion of contract. A period of two (2)
weeks from the dates of receipt of drawings by the ENGINEER shall be
anticipated for this item of procedure in the schedule.
5.2.16 All fabrication drawings submitted by the CONTRACTOR will remain the
property of the OWNER. OWNER reserves the right to use them in any manner
whatsoever.
6.0 FABRICATION
6.1 GENERAL
6.1.1 Fabrication shall not be started until CONTRACTOR has received copies of
such drawings upon which ENGINEER has endorsed his approval. Any work
done prior to approval of CONTRACTOR’s fabrication drawings will be at the ISSUE
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CONTRACTOR's risk. The CONTRACTOR shall make such changes in the

design when so directed, which are considered necessary to make the
structures conform to the provisions and intent of the specifications, without
any additional cost to the OWNER.
6.1.2 All workmanship and finish shall be of the best quality and shall conform to
good engineering practice and the best-approved method of fabrication. All
materials shall be finished straight and shall be machined / ground smooth,
true and square where so specified.
6.1.3 All holes and edges shall be free of burrs. Shearing and chipping shall be
neatly and accurately done and all portions of work exposed to view shall be
neatly finished. Standard fabrication clearances as detailed in the American
Institute of Steel Construction Manual / BIS Codes shall generally be followed
unless otherwise directed / approved.
6.1.4 Materials at the shop shall be kept clean and protected from weather. Cutting,
punching, drilling, welding and fabrication tolerances shall be generally as per
relevant Codes and Standards. In addition, the CONTRACTOR shall strictly
adhere to the following.
a) All care shall be taken to avoid undue welding distortions.

b) Complete layout shall be prepared and got approved by the ENGINEER before
actual fabrications are started. If needed mock-ups may also be prepared.
c) All fit ups shall be got approved from the ENGINEER.
6.2 CONNECTIONS
6.2.1 All shop connections shall be welded unless otherwise specified in

ENGINEER’s design drawing. Field connections can be either welded or
bolted and as shown in design drawings. Bolts used for erection shall conform
to IS-6639 and as specified in the design drawings. Bolts used for permanent
connections shall be high strength tensile bolts and shall conform to grade ‘C’
as per IS: 1363 and property class 8.8 (minimum) as per IS: 1367 or as
indicated in design drawings.
6.2.2 All connections shall be designed for forces indicated on the design drawings
or as specified elsewhere in the specification/standard drawing if not given in
the design drawings. The CONTRACTOR shall be responsible for selection of
standard connections from AISC Manual of Steel Construction or any other
standards approved by ENGINEER.
6.2.3 All connections shall be designed and detailed as per guidelines given in IS:
800:2007.
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6.2.4 In case of bolted connections, taper washers or flat washers or spring washers
shall be used with bolts as necessary. In case of high strength friction grip bolts,
hardened washers are used under the nuts or the bolt heads whichever are
turned to tighten the bolts. The length of the bolt shall be such that at least one
thread of the bolt projects beyond the nut, except in case of high strength
friction grip bolts where this projection shall be at least three times the pitch of
the thread.
6.2.5 In all cases where bearing is critical, the unthreaded portion of bolt shall bear
on the members assembled. A washer of adequate thickness may be provided
to exclude the threads from the bearing thickness, if a longer grip bolt has to
be used for this purpose.
6.2.6 Not more than one shop splice shall be provided to make up the full length of
a member. Shop splices to make the full member lengths shall be of full
penetration butt welded type and radiographically tested.
6.2.7 Transportation or the CONTRACTOR’s erection methods may require

additional splices not shown on the drawings. The CONTRACTOR shall be
responsible for the design and detailing of such splices or joints and shall
submit these for the ENGINEER’s approval. CONTRACTOR shall take utmost
care to prevent any kind of distortion of the fabricated members that are being
transported.
6.2.8 All bolts, nuts, screws, washers, electrodes, etc. shall be supplied / brought to
site 10% in excess of the requirement in each category and size. Rates shall
cover the cost of this extra quantity and no additional payment will be made for
this extra quantity supplied.
6.2.9 All members likely to collect rain water shall have drain holes provided.
6.3 STRAIGHTENING
6.3.1 Rolled material, before being worked, shall be straightened, unless otherwise
specified. If straightening or flattening is necessary, it shall be done by methods
that will not injure the material. Long plates shall be straightened by passing
through a mandrel or levelling rolls and structural shapes by the use of
mechanical or hydraulic bar/section straightening machines. Heating or forging
shall not be resorted to without the prior approval of the ENGINEER in writing.
In case of site fabrication, CONTRACTOR shall obtain ENGINEER’s approval
in writing on the straightening method proposed to be adopted before
commencing the work.
6.3.2 Checking of the straightness of the structural members like angles, channels,
beams etc. shall be done by using the thread. For checking of the straightness
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of the column sections piano wire shall be used. The sections, which are R9

twisted beyond repairs, shall not be used for fabrication. Heating or hammering
shall not be permitted. After removal of bends structural members shall be
submitted for inspection and approval of ENGINEER.
6.4 CUTTING
6.4.1 Cutting may be done by shearing, cropping, sawing or machine flame cutting.
All re-entrant corners shall be shaped notch free to a radius of at least 12-mm.
Sheared or cropped edges shall be dressed to a neat workmanlike finish and
shall be free from distortion and burrs.
6.4.2 Hand flame cutting shall be undertaken, only if so permitted by the ENGINEER
and shall only be carried out by an expert in such work. Hand flame cut edges
shall be ground smooth and straight.
6.4.3 Edges of flange cover plates and plates used to form any sections shall be
ground smooth.
6.5 PUNCHING AND DRILLING
6.5.1 Holes in secondary members such as Purlins, girts, lacing bars etc. may be
punched full size through material not over 12 mm thick. Holes shall be clean
cut, without burr or ragged edges. Holes for all other connections shall be
drilled accurately and the burrs removed effectively. Where several parts are
to be connected to very close tolerances such parts shall be first assembled,
tightly clamped together and drilled through.
6.5.2 Sub-punching may be permitted before assembly, provided the holes are
punched 3 mm smaller in diameter than the required size and reamed after
assembly to the full diameter. The thickness of material punched shall not in
such cases exceed 16 mm.
6.5.3 When match drilling is carried out in one operation through two or more
separate parts, these parts shall be separated after drilling and the burrs
removed.
6.5.4 Holes for turned and fitted bolts shall be drilled with diameter equal to the
nominal diameter of the shank or barrel subject to tolerance specified in IS:
919.
6.5.5 Where reamed members are taken apart for transporting or handling, the
respective pieces reamed together shall be so marked that they may be
reassembled in the same position in the final setting up. No interchange of
reamed parts will be permitted. Poor matching, over drilling and ovality in holes
shall be a cause for rejection. Burning holes with gas is strictly prohibited.
6.6 ROLLING AND FORMING
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Plates, Channels, Rolled Steel joists etc., for circular bins, bunkers, hoppers,
gantry girders, etc., shall be accurately laid off and rolled or formed to required
profile/ shape as called for on the drawings. Adjacent sections shall be match-
marked to facilitate accurate assembly, welding and erection in the field.
6.7 GRINDING:
Column ends bearing on each other, resting on base plates, compression joints
designed for bearing, base plates coming in contact with column end and cap
plate shall be ground smooth to ensure 90% contact with local gap not
exceeding 0.10 mm (filler gauge shall be used to check this gap). Bottom edge
of knife edge support (bearing stiffener) for crane girder and top of cap plates
where the knife edge supports rest shall also be accurately ground as above.
All ground surfaces shall be protected from dirt and mechanical damages till
the assembly is completed. However, the underside of base plate bearing on
grout need not be machined.
6.8 WELDING
6.8.1 Before the start of the work, welding procedure shall be submitted to
ENGINEER for approval. Welding shall be entrusted to only qualified and
experienced welders who shall be periodically tested and graded as per
relevant standards. The CONTRACTOR shall maintain and update the
welder’s records as and when the tests are conducted.
.
6.8.2 Welding procedure specification (WPS) shall be established and Qualification
of weld procedure (QWP) shall be done as per approved standards. Welders
employed shall also be qualified as per above standards prior to taking up
fabrication. CONTRACTOR shall obtain approval from ENGINEER before the
start of the work.
6.8.3 Following pre-qualified welding process shall be employed for fabrication,

erection and repair and the same shall have the approval of ENGINEER before
adopting the welding process on the job.
a) Submerged Arc Welding (SAW).

b) Shield Metal Arc Welding (SMAW).
c) Gas Metal Arc Welding (GMAW).
d) Gas Tungsten Arc Welding (GTAW)
6.8.4 All welds shall be free from defects like blowholes, lack of penetration,
undercutting, cracks etc. All welds shall be cleaned of slag or flux and show
sections, smoothness of weld metal, featheredges without overlap and freedom
from porosity.
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6.8.5 50mm on either side of the surfaces on which weld metal is to be deposited
shall be smooth, uniform, free from fins, tears, burrs, cracks and absolutely free
from grease, paint, loose scale, moisture or any other substance which would
adversely affect quality and strength of weld.
6.8.6 Machining, thermal cutting or grinding may be employed for joint preparation or
removal of unacceptable work or metal. The weld edges shall be smooth &
regular surface, free from cracks & notches. Flame cut material above 50mm
thick shall be pre-heated as per relevant standards prior to flame cutting and
shall be subjected to ENGINEER’s approval.
6.8.7 All weld fit-up shall comply with tolerances specified in the relevant standards.
The parts to be joined by fillet welds shall be brought into close contact as
practicable and within the tolerable limits as per relevant codes & standards.
6.8.8 All tack welds shall be made using qualified procedure and qualified welders.
Any preheat requirement specified in the welding procedure shall also apply to
tack welds. All tack welds shall be examined visually for defects and if found
defective, shall be removed and re-welded. Throat thickness, leg length and
length of tack weld shall be as per IS: 9595.
6.8.9 Welding of temporary attachment/fixtures to retain fit up is permitted in case

the parts have a nominal thickness of at least 10 mm. Temporary attachments
are welded at the minimum distance of at least 50 mm from the weld seam.
Welding of temporary attachments/fixtures into the joint slot is not allowed. All
temporary fixtures shall be removed after welding, by grinding them to weaken
the welded portion and hammering thereafter followed by grinding the portion
of any weld remaining on the base metal. A dye check at the discretion of the
quality surveyor shall be done to detect any crack/defect at the point of fixture
temporary weld.
6.8.10 It is not allowed to turn over and carry over heavy assemblies in tacking
condition in order to control the geometric dimensions to the requirements of
the drawings. The work shall be positioned for flat welding wherever practicable
and overhead weld shall be avoided as far as possible.
6.8.11 In the joints of the parts with dissimilar thickness smooth transition of one part
to the other must be provided by way of the gradual decreasing of the thickness
of the thicker part with the slope of the surface not exceeding 15 degree or 1:5.
6.8.12 Welding shall not be done when the surface of the members are wet or exposed
to rain or high wind velocities unless the welding operator and the work are
properly protected.
6.8.13 In joints connected only by fillet welds, the minimum size of fillet weld to be
used shall be as per IS 9595-1996.
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6.8.14 Welds shall be defect free and surfaces shall be thoroughly cleaned to remove
all visible weld defects and extra material.
6.8.15 For all built up sections such as Columns/ girders/ beams, Crane Girders etc.,
welding between web and flange plates shall be carried out by SMAW / SAW
process. Welding shall be continuous and shall be on both sides of the
connecting member. One side fillet weld is not acceptable. Especially for butt
welds of Crane girders full penetration of weld between top of web plate and
top flange shall be ensured.
6.8.16 In general, all welding shall be performed as per the recommendation specified
in IS: 9595-1996.
6.8.17 Pre-heating and Post weld Heat treatment shall be carried out as per the
acceptable standards and procedure and shall have prior approval from the
ENGINEER. The pre-heat and inter pass temperature shall be checked just
prior to initiating the arc for each pass. The weld joint details and procedure for
Pre-heating and Post heating shall be submitted by the CONTRACTOR for
approval from ENGINEER.
6.9 WELDING CONSUMABLES.
6.9.1 Electrodes, filler wires and flux used for welding shall be from approved
manufacturers/Suppliers. CONTRACTOR shall submit the list of Electrode
manufacturers proposed to be procured to the ENGINEER for approval. The
CONTRACTOR shall furnish certification that electrode or electrode flux
combination will meet the requirements of classification. The classification and
size of electrode, arc length, voltage & amperage shall be suited to type and
thickness of material, type of groove, welding positions and other
circumstances attending work.
6.9.2 Only low hydrogen electrodes shall be used for welding 20mm and above thick
plates. All electrodes having low hydrogen covering shall conform to relevant
acceptable standards. These electrodes shall be purchased in hermetically
sealed containers or baked by the user as recommended by electrode
manufacturer. Electrode flux coating shall be sound and unbroken. Broken or
damaged coating shall cause the electrodes to be discarded. Before welding,
the electrodes shall de dried in a holding oven as per manufacturer’s
recommendations. Only limited quantity shall be issued to the welders. The
electrodes shall be kept in “carry ovens” and shall not be exposed to the
atmosphere.
6.9.3 Welding plants and accessories shall have capacity adequate for welding
procedure laid down and shall satisfy appropriate standards and be of
approved make and quality. CONTRACTOR shall furnish and obtain approval
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from ENGINEER the details of equipment he proposes to deploy for the works. R9

All the electrical plant in connection with the welding operation shall be properly
and adequately earthed and adequate means of measuring the current shall
be provided. Proper safety rules shall be strictly followed.
7.0 TESTING, INSPECTION AND REPORTS
7.1 GENERAL.
7.1.1 On award of work, the CONTRACTOR shall submit to ENGINEER,

his Quality Assurance Plan (QAP), outlining the types, details and
extent of inspection he proposes to execute, covered in the rates
quoted for various items of work.
7.1.2 CONTRACTOR shall give due notice to ENGINEER in advance of the

materials or workmanship getting ready for inspection. All rejected
material shall be promptly removed from the shop and replaced with
new material for ENGINEER’s approval / inspection. The fact that
certain material has been accepted at CONTRACTOR’s shop shall
not invalidate final rejection at site by ENGINEER if it fails to conform
to the requirements of these specifications, be in proper condition or
has fabrication inaccuracies which prevent proper assembly.
7.1.3 No material shall be painted or dispatched to site without the

inspection and approval by ENGINEER unless such inspection is
waived in writing by the ENGINEER.
7.1.4 Shop inspection by ENGINEER or submission of test certificates and

acceptance thereof by ENGINEER shall not relieve CONTRACTOR
from the responsibility of furnishing material conforming to the
requirements of these specifications, nor shall it invalidate any claim
which the ENGINEER may make because of defective or
unsatisfactory material or workmanship.
7.1.5 CONTRACTOR shall provide all the testing and inspection services
and facilities for shop work except where otherwise specified.
7.1.6 For fabrication work carried out in the field, the same standard of
supervision and quality control shall be maintained as in shop
fabricated work. The inspection and testing shall be conducted in a
manner satisfactory to ENGINEER. The inspection and testing on
structural steel members shall be as set forth below:
7.2 MATERIAL TESTING.
7.2.1 All materials conforming to a particular Indian or any other standard as

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called for shall be tested as required by such standard. Proof in the R9

form of certified test reports or mill certificates indicating that the

required tests have been carried out as per specification at the source
is acceptable.
7.2.2 If mill test reports are not available for any steel materials, the same
shall be got tested by CONTRACTOR to ENGINEER’s satisfaction to
demonstrate conformity with the relevant specification at his own cost.
For materials supplied by OWNER, the cost of such tests will be
reimbursed to CONTRACTOR. Testing shall be conducted at NABL
accredited laboratories or Owner Approved labs.
7.2.3 Raw material with cracks, seams, laps, lamination and heavy pitting are
not acceptable. Ultrasonic testing of plates above 50 mm thick shall
be carried out for the soundness of material, the same shall be got
tested by CONTRACTOR to ENGINEER’s satisfaction to
demonstrate conformity with the relevant specification at his own cost.
For materials supplied by OWNER, the cost of such tests will be
reimbursed to CONTRACTOR.
7.2.4 Engineer has option to specify additional inspection or testing as he

deems necessary for materials supplied by CONTRACTOR, and the
additional cost of such testing shall be reimbursed to the
CONTRACTOR. However, if the tests fail, then the costs of these
tests will be borne by CONTRACTOR.
7.2.5 The CONTRACTOR shall maintain records of all inspection and tests,
which shall be made freely available to the ENGINEER and shall be
submitted to the ENGINEER on completion of each stage of work.
7.3 TESTS ON WELDS
7.3.1 All welds shall be tested for flaws by any of the methods described
under. The choice of the method adopted shall be determined by the
OWNER. Following methods are generally recommended for the
quality control of welded joints:
7.3.2 Magnetic Particle Test (MPT):
All fillet welds in general structural steel work shall have their final passes fully
tested by MPT. However, for fillet welds of size 10mm and above and /or critical
areas, the root and final passes shall be tested using MPT. The ENGINEER
shall however decide the requirements of this additional testing. For Complete
penetration butt welds, the root and final passes shall be tested using MPT. All
MPT shall be as per relevant acceptable standards. Defects if found, shall be
repaired and retested. MPT shall be carried out using alternating current only.
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Direct current may be used with the permission of the ENGINEER. The cost of R9

demagnetizing after testing is deemed to be included in the quoted rates of the

CONTRACTOR.
7.3.3 Dye Penetrant Test (DPT):
Dye penetrant testing shall be in accordance with relevant standards.
7.3.4 Radio-graphic Inspection (RT):
All completed full penetration butt welds to a length of about 10% shall be radio-
graphed as per ENGINEER’s directive in accordance with the relevant
acceptable standards. In case of crane girders 100 per cent of the full strength
butt welds shall be inspected by RT. In the case of hoppers of coal bunkers at
least 10% of the circumferential as well as seam welds shall be inspected by
RT or as per mutual agreement in % between the OWNER and
CONTRACTOR.
.
7.3.5 Ultrasonic Testing (UT):
Wherever built up sections for crane runway girders are fabricated, the T-joints
of the sections shall be subjected to ultrasonic testing. 100 per cent length of
the seam as well as circumferential welds of hoppers of coal bunkers shall be
inspected by UT; OR as per mutual agreement between the OWNER and
CONTRACTOR.
.
7.3.6 Acceptance Standard:
The acceptable standards for various weld tests shall be as per ASME Sec IX
or relevant acceptable standards.
7.4 INSPECTION OF WELDS.
7.4.1 Welding shall be carried out as per approved WPS and QWS by
qualified welders.
7.4.2 All welds shall be inspected for flaws by any of the methods
described under clause 7.3; the choice of the method adopted shall
be determined by the ENGINEER.
7.4.3 The correction of defective welds shall be carried out as directed by

the ENGINEER without damaging the parent metal. When a crack
in the weld is removed, magnetic particle inspection or any other
equally positive means as prescribed by the ENGINEER shall be
used to ensure that the whole of the crack and material up to 25 mm
beyond each end of the crack has been removed. Cost of all such
tests and operations incidental to correction shall be to the
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7.4.4 CONTRACTOR shall perform the following minimum tests on welds

if not covered in clause 7.3.2 to 7.3.5 above, with no cost implication
to the OWNER. CONTRACTOR’s quoted rate is deemed to have
included the cost of such tests.
Sl Location & Type of Type of Test Extent of test Remarks

N weld
o
1. All fillet welds in DPT 1% of fillet
general other than weld with
those covered under minimum of
the Sl no 2 ,3,5,7 & 8 one test on
each member /
joint
2. Fillet welds for plate MPT/ DPT 10%
thickness greater than
25 mm and fillet size
more than 10 mm
3. Flame cut edges of MPT / DPT 100%
plates more than 38
mm for fillet weld
4. Flame cut edges of MPT / DPT 100%
plates greater than 25
mm for butt welds,
5. Fillet welds between MPT / DPT 100%
tension flanges and
webs
6. Full penetration butt DPT 100 % DPT shall be
welds carried out after
back gouging
before second
side welding
7. Fillet Weld greater MPT 100%
than 12 mm on flame
cut edges of low alloy
steel
8. Fillet Welds for built up Macro etch One (1) test
girders, columns and test per structure
other heavy structures for penetration
for penetration.
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9. Butt welds of thickness MPT / DPT 100 %

greater than 25 mm
and less than 32 mm
10. Butt welds of thickness RT 100%
greater than 32 mm
11. Butt welds of rolled RT 100%
sections having depth
greater than 600 mm
7.4.5 In addition to the minimum tests to be conducted by the CONTRACTOR,

ENGINEER reserves his right to direct the CONTRACTOR to conduct
additional tests. The extent, type and location of test shall be decided by the
ENGINEER. These additional tests shall be conducted by the CONTRACTOR
or through an approved agency in presence of the ENGINEER. If the test fails,
the cost of that test shall not be payable to the CONTRACTOR. The tests which
when successful will be paid for at the rates specified in the schedule.
7.4.6 WELD DEFECTS AND ACCEPTABLE CRITERIA
Type of defect Acceptance criteria Remarks

Cracks Not acceptable
Incomplete or lack of Not acceptable
Fusion
Mis-alignment of butt 0.25 x T (maximum of 3 mm) T: Thickness of thinner
welds plate
Reinforcement Max reinforcement of
2 mm for t < 10 mm
3 mm for t > 10mm < 15 mm.
4 mm for 15 mm and greater
Undercut 0.25 mm deep max
Sharp edges Min radius of 2 mm
7.4.7 WELD REPAIRS

Whenever weld repair is required, CONTRACTOR shall give prior intimation to
the ENGINEER and obtain permission before the repair is taken up. When a
defect is detected in a weld, it shall be removed by cutting / grinding and smooth
blending of the area with parent metal without sharp edges, corners. If welding
is required, the same shall be done using the qualified procedure / welder and
stage inspection as per the original weld. Correction of defect in the same ISSUE
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portion of the weld shall not be allowed more than two (2) times. Portion of the
welding seams, which have been subjected to repair, must be indicated in the
weld inspection reports.
8.0 INSPECTION AND TESTS ON STRUCTURAL STEEL FABRICATED

MEMBERS
Inspection and tests on Structural Steel Fabricated Members shall be as set

forth below:
8.1 All the fabricated parts of Structural Steel members shall be inspected at all
stages of fabrication and assembly to verify that dimensions, tolerances,
alignment and surface finish are in accordance with the requirements shown
on the approved CONTRACTOR's shop drawings and/or ENGINEER’s
drawings.
8.2 Fit ups shall be examined by the quality surveyor as per the approved QA plan
prior to welding the joint. All welds shall be inspected for flaws by the method
described under the Clause 7.4 (Inspection Of welds).
8.3 The dimensions of the fit ups shall be maintained as specified in the fabrication
drawings.
8.4 Dimensions of all the assemblies and sub-assemblies shall be as per

fabrication drawings within the tolerances specified in IS: 7215.
8.5 TOLERANCES
The dimensional and weight tolerance for rolled shapes shall be in

accordance with IS: 1852 for indigenous steel and equivalent applicable
codes for imported steel. The tolerances for fabrication of structural steel shall
be as per IS: 7215.
9.0 TEST FAILURE
9.1 In the event of any failure of welding, structural steel members to meet
inspection or test requirements, the CONTRACTOR shall notify the
ENGINEER or his authorised representative. A design concession request has
to be made and got approved from the ENGINEER or his representative before
repair is undertaken. The quality control procedures to be followed to ensure
satisfactory repair shall be subject to approval by ENGINEER.
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9.2 CONTRACTOR shall maintain records of all inspection and testing which shall
be made available to the ENGINEER or his authorised representative, for three
years from the date of completion of the contract.
9.3 The ENGINEER has the right to specify additional testing as he deems
necessary, and the additional cost of such testing shall be borne by the
OWNER only in case of successful testing.
10.0 SHOP MATCHING
For structures like bunkers, tanks, etc. shop assembly is essential. For other
steel work, such as columns along with the tie beams/bracings may have to be
shop assembled to ensure satisfactory fabrication, obtaining of adequate
bearing areas etc. if so desired by the ENGINEER. All these shop assemblies
shall be carried out by CONTRACTOR at no extra cost to the OWNER.
11.0 DRILLING HOLES FOR OTHER WORKS
As a part of this Contract, holes in members required for installing equipment

or steel furnished by other manufacturers or other CONTRACTORs shall be
drilled by the CONTRACTOR at no extra cost to the OWNER. The information
for such extra holes will be supplied by the ENGINEER.
12.0 MARKING OF MEMBERS
12.1 After checking and inspection, all members shall be marked for identification
during erection. This mark shall correspond to distinguishing marks on
approved erection drawings and shall be legibly painted and stamped on it.
The erection mark shall be stamped with a metal dye with figures at least 20
mm high and to such optimum depth as to be clearly visible.
12.2 All erection marks shall be on the outer surface of all sections and near one
end, but clear of bolt holes. The marking shall be so stamped that they are
easily discernible when sorting out members. The stamped marking shall be
encircled boldly by a distinguishable paint to facilitate easy location.
12.3 Erection marks on like pieces shall be in identical locations. Members having
lengths of 7.0 m or more shall have the erection mark at both ends.
13.0 ERRORS
Any error in shop fabrication which prevents proper assembling and fitting up
of parts in the field by moderate use of drift pins or moderate amount of
reaming will be classified by the ENGINEER as defective workmanship. In
case ENGINEER rejects such material or defective workmanship, the same
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shall be replaced by the materials and workmanship conforming to the R9

ENGINEER’s requirements by CONTRACTOR free of cost at site. All the

costs of removal, handling, rectification, refitting and any other cost incidental
to faulty workmanship shall be borne by the CONTRACTOR.
14.0 SHOP PAINTING
Surface preparation and painting of steel surfaces shall be in accordance with

TCE specification M4-405-04.
15.0 QUALITY SURVEILLANCE
15.1 GENERAL.
15.1.1 The ENGINEER shall subject all works and materials covered by this
specification to Inspection.
15.1.2 The CONTRACTOR shall provide free access in his shop during working hours
for the inspection staff, designated by the Engineer, at all phases of the work
and assist them where necessary in conducting the inspection. The
CONTRACTOR shall expeditiously furnish all gauges, instruments and other
necessary measuring equipment required for inspection of the work in the shop.
The shop inspection by the inspector is intended to ensure that the material
and workmanship are in accordance with this specification, but it will not relieve
the CONTRACTOR of any of his responsibilities for the product. The
inspector’s inspection will include, but not be limited to, the following:
15.2 MATERIAL
The inspector will ascertain that only materials conforming to the requirements
of this specification are used.
15.3 DIMENSION AND TOLERANCES
The ENGINEER will ensure and check that the structural members conform to
the dimensions and tolerances as set out on the drawings and as required by
the specification.
15.4 WELDING PROCEDURE
The ENGINEER will witness the welding and testing of any procedure
qualification tests that are required by this specification. The ENGINEER will
also check that welding procedure (including the electrode, flux, current, arc
voltage, speed of travel) used are in accordance with the approved welding
procedures.
15.5 WELDING EQUIPMENT

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The ENGINEER will check the welding equipment to be used for the work to
ensure that it is in such condition as to enable qualified welders to follow the
procedures.
15.6 WELDER AND WELDING OPERATOR QUALIFICATIONS
15.6.1 The ENGINEER will permit welding to be performed only by welders and
welding operators who are qualified by tests in accordance with relevant
standards
15.6.2 When the quality of a welder or welding operators’ work, appears to be below
the requirements, the ENGINEER may require testing of his qualifications by
necessary tests.
15.7 WELDS
15.7.1 The ENGINEER will ascertain that the sizes, length and the location of all welds
conform to the requirements of this specification and the approved fabrication
drawings. Temporary welds used for the works shall be removed and ground
flush with the original surface.
15.7.2 The ENGINEER will identify with a distinguishing mark of all parts of the joints
that he has inspected and accepted.
15.7.3 The CONTRACTOR shall comply with all the demands of the ENGINEER to
correct improper workmanship and to remove and replace, or correct as
instructed, all welds found defective or deficient.
15.7.4 In the event of faulty welding or its removal for re-welding results in damage to
the base metal in the judgment of the Engineer, or its retention is not in
accordance with the intent of the plans and specification, the CONTRACTOR
shall remove and replace the damaged materials at his own cost.
16.0 METHOD OF MEASUREMENT
16.1 For the purpose of payment, the weight of the actual completed structures
shall be calculated from the approved drawings for different finished structural
elements and for different items of work. The CONTRACTOR shall submit to
the OWNER relevant material list containing weight of each item.
16.2 No allowances will be permitted for bolts, nuts, washers, studs, screws etc.,
galvanizing, welding or for rolling margins. One tonne for the purpose of
payment shall mean ONE METRIC TONNE i.e. 1000 Kg. Permanent bolts,
however, will be considered for payment against the relevant item under
schedule of items.
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16.3 The weight of a member made out of standard rolled section such as beams,
channels, angles, etc., shall be based on the standard IS:808 without
deductions for holes, notches, bevel cuts, etc. Where a component consists
of a cut rolled sections, the full weight of the rolled section shall be considered
only if more than half the depth of the original section is used. Otherwise,
only half the section unit weight shall be considered for calculation of the
weight of the components. Deductions shall be made in the weight of
gussets/plates for cuts and notches of 900 sq. cm. or larger.
16.4 For gussets/plates used in trusses, bracings, columns, beams, etc., the area
shall be that of the minimum circumscribing rectangle except as stated in 16.3
above.
The weight of any built-up members shall be based on the weight of each
component.
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TCE.M4-405-02 ERECTION OF STRUCTURAL STEEL SHEET 1 OF 14
1 SCOPE
This specification covers the general requirements for erection of structural
steel. In addition to erection of steel, transportation of fabricated steel from
fabrication yard to storage yard, transportation of associated equipment are a
part of the scope of works. The scope of work also includes supply of tools
and tackles, consumables, materials, labour and supervision and shall also
cover the following:
1.1 Storing and stacking of all fabricated structural components/units/assemblies
at site storage yards till the time of erection.
1.2 Transportation of structures from storage yard to site of erection, including
multiple handling, if required.
1.3 All minor rectifications/ modifications such as:-
i) Removal of bends, kinks, twists etc., for parts damaged during
transportation and handling
ii) Reaming of holes which do not fit properly or which are damaged, for
use of next higher size bolt.
iii) Plug-welding and re-drilling of holes which do not register, and which
cannot be reamed for use of next higher size bolt.
iv) Drilling of holes which are either not drilled at all or are drilled in incorrect
position during fabrication.
1.4 Fabrication of minor missing items as directed by the OWNER.
1.5 Verification of the position of embedded anchor bolts and inserts w.r.t lines
and levels, installed by others based on Geodetic Scheme /Bench
Mark/Reference co-ordinates to be furnished by OWNER.
1.6 Verification of actual dimensions of structures (erected by others) which would
have bearing on the cutting lengths, end connections etc., of those members
which are to be erected under this scope of work.
1.7 Assembly at site of steel structural components wherever required, including
temporary supports and staging.
1.8 Making arrangements for providing all facilities for
i) Conducting Ultrasonic Testing (UT) by reputed testing laboratories
approved by OWNER.
ii) Making available test films / graphs, with reports / interpretation.
1.9 Rectifying at site; damaged portions of shop primer by cleaning and
application of touch-up paint.
1.10 Erection of structures including making connections by bolts/ High strength
Friction Grip bolts / welding as per drawing.
FILE NAME: M4-405-02-Rev-09.docx

herewith. In consideration of receipt of this document; unless agreed to in contrary in the Contract; the recipient agrees to maintain such information in confidence and to not reproduce or otherwise disclose this ISSUE
from Tata Consulting Engineers Limited, or becomes publicly known through no fault of recipient, or Tata Consulting Engineers Limited, or is received without obligation of confidentiality from a third party owing no R9
subsequently communicated in writing) or in writing or otherwise given under any and all previous version/s.

TCE.M4-405-02
ERECTION OF STRUCTURAL STEEL SHEET 2 OF 14
1.11 Alignment of all structures true to line, plumb and dimensions within
specified limits of tolerance.
1.12 Application at site after erection, required number of coats of primer and
finishing paint as per specification.
1.13 Rectification of structures as per preliminary acceptance report and Final
acceptance report.
1.14 All necessary items of work required for satisfactory completion of job on
schedule.
2 APPLICABLE CODES STANDARDS & SPECIFICATIONS
The pertinent clauses of the following Indian Codes, Standards and
Specification (latest editions including all applicable official amendments,
reaffirmations and revisions) shall apply to the material and workmanship
covered by this specification. In the event of conflict of certain requirements
between this specification and the codes referred herein, this specification
shall govern.
It is not the intent to specify herein all the codes and standards required for
the satisfactory completion of work. The list of codes and standards indicates
certain primary codes & standards and not all the codes required for the work
under the contract. It is understood that all the pertinent codes and standards
shall form the part of this specification whether explicitly indicated or not.
Reference codes and standards:
IS 800: 2007 General Construction in Steel –Code of Practice.
(Reaffirmed 2017)
IS 806:1968 Code of Practice For Use Of Steel Tubes In
(Reaffirmed 2017) General Building Construction
IS 808:1989
Dimensions for hot rolled steel beam, column,
(Reaffirmed 2019
channel and angle sections
IS 822:1970 Code of Procedure for Inspection of Welds.
(Reaffirmed 2019
IS1363:2002 Hexagonal Head Bolts, screw and nuts of
Product grade “C” (Parts 1 to 8)
IS 1367:2002 Technical Supply Conditions for threaded
fastener (all parts)
IS 4000:1992 Code of Practice High strength bolts in Steel
(Reaffirmed 2013) Structures.
IS 7205:1974 Safety code for erection of structural steel
(Reaffirmed 2016)
IS 7969: 1975 Safety code for handling and storage of building
(Reaffirmed 2012) Materials
IS:9595:-1996 Metal Arc Welding of Carbon and Carbon
(Reaffirmed 2019 manganese steel.
IS 1182: 1983 Recommended Practice for Radiographic
(Reaffirmed 2017) examination of Fusion Welded Butt Joints in Steel
Plates
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TCE.M4-405-02
IS 2595:2008 Code of Practice for Radiographic Testing

(Reaffirmed 2013)
IS 1239:2017 Steel Tubes, Tubular and Other Wrought Steel
(Reaffirmed 2017) Fittings-Specification-Part 1: Steel Tubes
IS 12843:1989 Tolerances for erection of steel structures.
(Reaffirmed 2016)
IS 12778: 2004 Hot rolled parallel flange steel sections for
(Reaffirmed 2019) beams, columns and bearing piles - Dimensions
and section properties
AWS D1.1:2015 Structural Welding Code: Steel
Jindal steel Catalogue
SAIL steel catalogue
3 REGULATORY REQUIREMENTS
The work covered in this specification, shall comply with all relevant
government and local laws, regulations and standards. For subjects not
covered by regulations, codes, standards or specifications, the materials
and construction shall be based on good engineering practice, subject to
approval by OWNER.
4 ERECTION SCHEME
4.1 CONTRACTOR after the award of work shall submit a detailed erection
scheme covering the period of completion of all the works covered under the
specification for ENGINEER’s approval. The erection scheme shall include
but not limited to the following.
i) Methods proposed to be employed for transporting his equipment,
tools, tackles, gas cylinders, electrodes and all that is necessary to
site.
ii) Type, capacity and quantity of equipment that the CONTRACTOR
proposes to bring to site for unloading, transporting within the site,
handling, assembling, hoisting and erecting of the structural steel
components.
iii) Strength and trade wise composition of the work force and supervisory
personnel that will be deployed by the CONTRACTOR for the various
operations.
iv) Erection scheme being adopted for erection of special / complicated
structural elements such as coal bunkers, chimney flue can, main
process building roof trusses etc.
4.2 A brief write-up covering the above activities shall be submitted along with
the bid document by the bidder during submission of his bid.
4.3 Engineer reserves the right to direct the contractor either at the start or
during the contract period, to mobilize additional resources in terms of
labour, material ,equipment, tools and plant etc., at no cost to the owner if in
his opinion that the resources employed by the contractor does not meet the
schedule of completion.
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5 ERECTION PROGRAMME
5.1 Within two (2) weeks of acceptance of bid the CONTRACTOR shall submit
a detailed erection programme with dates and estimated completion time for
various parts of the work for ENGINEER’s approval. This programme shall
broadly comprise the following:
i) Layout plan identifying the areas proposed for unloading, main
storage, subsidiary storage and assembly
ii) Transportation of fabricated material between the storage and work
areas.
iii) Layout to indicate the points at which proposed erection begins,
direction in which it is proposed to progress, the deployment of
equipment, access route for cranes to reach work areas, etc.
iv) The locations and extent of site offices and stores, labour quarters if
any.
v) Layout of electrical cables and water pipes from the tap-off points.
vi) Details of the method of handling, transport, hoisting and erection
including false work/staging, temporary bracing, guying, etc. along
with complete details of the quantity and capacity of the various items
of erection equipment that will be used.
vii) Site organization chart showing the number of supervisory personnel,
and the number and composition of the various gangs.
viii) Safety measures to be adopted at site of erection and organization
chart showing safety personnel.
5.2 Any modifications to the erection programme directed by ENGINEER for the
reasons of inadequacy of
i) The quantity and/or capacity of the erection equipment.
ii) Erection personnel and supervisors, temporary bracing, guying etc.,
iii) Safety of the erection methods, or stability of the erected portions of
structures, or unsuitability of the erection sequence due to interference
with the work of other agencies.
iv) Any other unforeseen events which may delay the schedule.
v) Safety measures proposed.
shall be incorporated by CONTRACTOR and the work shall be carried out
in accordance with the revised programme. Approval by ENGINEER shall
not relieve the CONTRACTOR from the responsibility for the safe, sound,
accurate and timely erection of structural steel work as required by
ENGINEER/OWNER. CONTRACTOR shall also make no extra claims for
bringing additional equipment to site for erection, if so directed by
ENGINEER. CONTRACTOR shall be deemed to have visualized all erection
problems while bidding for the work and no additional compensation shall
be claimed on this account.
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6 SITE OPERATIONS
6.1 CONTRACTOR shall employ an experienced and qualified graduate
Engineer who shall be in full time charge of the job and responsible for all
site activities.
6.2 CONTRACTOR shall complete all preliminary works at site well before the
arrival of structural steel, such as establishment of a well-equipped and
adequately staffed site office, stores, unloading gantry, unloading and pre-
assembly yard, labour quarters if any, electrical and water connections,
electrical winches, derricks, cranes, compressors, all tools and tackles, rivet
guns, welding sets, torque wrenches, spud wrenches, staging, etc. as well
as experienced erection and supervisory personnel as part of this contract
and any other work that may be necessary so as to start erection
immediately after the arrival of fabricated steel at site.
6.3 CONTRACTOR shall furnish at his own expense, the necessary non-
inflammable staging and hoisting materials or equipment required for the
erection work and shall remove and take them away after completion of the
job. CONTRACTOR shall also provide necessary passageways, fences,
safety belts, helmets, lights and other fittings to the satisfaction of OWNER
/ ENGINEER and to meet the rules of local authorities and for protection to
his men and materials. A licensed electrician shall be kept on the job for the
entire duration of the work to maintain CONTRACTOR’s electrical
equipment and connections.
6.4 CONTRACTOR shall protect all existing plant, structures, piping, conduits,
equipment and facilities against damage during erection. Any damage
caused by CONTRACTOR shall be rectified entirely at CONTRACTOR’s
cost, to the satisfaction of OWNER / ENGINEER. If work has to be carried
out adjacent to existing switch yards or electrical installations which are live,
CONTRACTOR must ensure suitable safety precautions in consultation with
ENGINEER.
6.5 If a portion of the work of the project area cannot be made available to
CONTRACTOR for his activities due to operations being carried out by other
agencies, he shall suitably modify his sequence of operations so as to
continue work without interruption. CONTRACTOR shall work in
coordination with other agencies working on the project site and plan his
work suitably so as not to hinder the progress of construction at site.
6.6 The Suitability and capacity of all plant and equipment used for erection shall
be to the satisfaction of the OWNER/ENGINEER.
7 ACCEPTANCE, HANDLING AND STORAGE
7.1 The fabricated material received at erection site shall be verified with respect
of marking on the key plan / marking plan or shipping list.
7.2 Any material found damaged or defective shall be stacked separately and
the damaged or defective material shall be painted in distinct colour for
identification and the same shall be brought to the notice of ENGINEER.
7.3 No dragging of steel shall be permitted. All fabricated items shall be stored
300mm above ground on suitable packing to avoid damage. It shall be
stored in the order required for erection, with erection marks visible. All
storage areas shall be prepared and maintained by CONTRACTOR. Before ISSUE
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TCE.M4-405-02
storing of Material, the Storage yard shall be marked on the plot plan and
CONTRACTOR shall get approval from OWNER/ ENGINEER.
7.4 Scratched or abraded steel shall be given a coat of primer in accordance with
TCE specification M4-405-04 (painting of structural steel) after unloading and
handling prior to erection. All milled and machined surfaces shall be properly
protected from rust/corrosion by suitable coating and from getting damaged.
8 ANCHOR BOLTS, EMBEDDED PARTS AND FOUNDATIONS
8.1 CONTRACTOR shall carefully check the location, level and layout of anchor
bolts embedded in foundations constructed by others, to ensure that the
structures can be properly erected as shown on the drawings. Any
discrepancy in the anchor bolts/foundation shall be reported to ENGINEER.
8.2 CONTRACTOR shall carefully check the actual dimensions of structures
and the location, level and sizes of embedded parts a) in the RC beam
/column and/ or b) cleats / plates provided in steel beam /column constructed
by others to receive structures covered under this scope of work.
CONTRACTOR shall take note of discrepancies if any and shall report to
ENGINEER and fabricate the structures covered under this contract suitably
before the commencement of erection.
8.3 Levelling of column bases to the required elevation may be done by
providing shims. All shim stock required for keeping the specified thickness
of grout and in connection with erection of structures on foundations, crane
brackets or at any other locations shall be of good M.S. plates and shall be
supplied by CONTRACTOR at his cost.
8.4 A certain amount of chipping/cleaning of foundations and preparing the area
is considered normal and shall be carried out by CONTRACTOR at no extra
cost.
8.5 Where beams bear in pockets or on walls, bearing plates shall be set and
levelled as part of the work. All grouting under column base plates or beam
bearing plates will be carried out by CONTRACTOR, unless the grouting is
specifically excluded from the CONTRACTOR’s scope.
9 ASSEMBLY AND CONNECTIONS
9.1 Field connections may be executed either by bolting, welding or by use of
high strength friction grip bolts as shown in the design and erection
drawings.
9.2 All bolts, nuts, washers, rivets, electrodes required for field connections shall
be supplied by CONTRACTOR free of cost. The materials shall have prior
approval from the OWNER /ENGINEER and necessary test certificates shall
be furnished for ENGINEER’s approval. Materials shall be procured from
reputed manufacturers with prior approval from OWNER /ENGINEER
9.3 All assembling shall be carried out on a level platform.
9.4 For frames especially in bolted construction, controlled assembly shall be
carried out in shop before material is sent to site to check the adequacy of
fit of the structural components.
9.5 Drifts shall be used only for drawing the work to proper position and must
not be used to such an extent as to damage the holes. Size of drifts larger
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TCE.M4-405-02
than the nominal diameter of hole shall not be used. Any damaged holes or
burrs must be rectified to the satisfaction of ENGINEER.
9.6 Corrections of minor misfits and reasonable amount of reaming shall be
considered as a part of erection. Any error in the shop, which prevents
proper fit on a moderate amount of reaming and slight chipping or cutting,
shall be immediately reported to ENGINEER.
10.0 ERECTION
10.1 Erection work shall be taken up after receipt of clearance from the
ENGINEER.
10.2 All structural steel shall be erected as per approved Design / fabrication
drawings.
10.3 For safety requirements during erection, provisions of IS: 7205, IS: 7969, IS:
800 and other relevant codes shall be strictly followed. The safety plan to be
prepared by CONTRACTOR and any erection activities shall start only after
getting approval from Owner/ Engineer on the safety plan.
10.4 Erection shall be carried out with the help of maximum mechanization
possible.
10.5 Prior to commencement of erection, all the erection equipment, tools,
tackles, ropes etc., shall be tested for their load carrying capacity. Such tests
may be repeated at intermediate stages also if considered necessary.
Frequent visual inspection shall be done of all vulnerable areas and
components to detect damages or distress in the erection equipment, if any.
10.6 Temporary bracing, whenever required, shall be provided to sustain forces
due to erection loads, equipment etc. Erected parts of the structure shall
remain stable during all stages of erection when subjected to action of wind,
dead weight, erection forces etc. Such bracings shall be left in place as long
as may be required for safety and stability. Specified sequence of erection
of vertical and horizontal structural members shall be followed. After
completion of all permanent member erection and alignment, the temporary
bracing shall be removed.
10.7 Erected members shall be held securely in place by bolts to take care of
dead load, wind / seismic load and erection load.
10.8 All structural members shall be erected with erection marks in the same
relative position as shown in the appropriate erection and shop drawings.
10.9 All connections shall achieve free expansion and contraction of structures
wherever provided.
10.10 No final bolting or welding of joints shall be done until the structure has been
properly aligned and approved by ENGINEER.
10.11 For positioning beams, columns and other steel members, the use of steel
sledges is not permitted.
10.12 Instrumental checking of correctness of initial setting out of structures and
adjustment of alignment shall be carried out in sequence and at different
stages as required using precision survey instruments. The final levelling
and alignment shall be carried out immediately after completion of each
section of a building.
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10.13 The CONTRACTOR shall design, manufacture, erect and provide false
work, staging, temporary support, etc., required for safe and accurate
erection of structural steelwork and fully responsible for the adequacy of the
same.
10.14 The CONTRACTOR shall also provide facilities such as adequate temporary
access ladders, gangways, tools & tackles, instruments etc., to OWNER for
his inspection at any stage during erection.
10.15 Proper size steel cable slings, etc., shall be used for hoisting. Guys shall
not be anchored to existing structures, foundations, etc. unless so permitted
by ENGINEER in writing. Care shall be taken to see that ropes in use are
always in good condition.
10.16 Steel columns in the basement, if any, are to be lowered and erected
carefully with the help of a crane and/or derrick without damaging the
basement walls steel or floor.
10.17 Structural steel frames shall be erected plumb and true. Frames shall be
lifted at such points that they are not liable to buckle and deform. Trusses
shall be lifted only at node points. Trusses which are very slender in the
lateral direction shall be provided with temporary lateral supports till the
horizontal bracings are erected. All steel columns and beams shall be
checked for plumb and level individually before and after connections are
made.
10.18 Chequered plates shall be fixed to supporting members by welding or by
countersunk bolts as shown/specified in relevant drawings and/or as
directed by ENGINEER. The edges shall be made smooth and no burrs or
jagged ends shall be left. While splicing, care should be taken so that there
is continuity in pattern between the two portions. Care should also be taken
to avoid distortion of the plate while welding. The erection of chequered
plates shall include:
a. Welding of stiffening angles/vertical stiffening ribs as per drawings
b. Cutting to size and making holes to required shape wherever
necessary to allow service lines such as piping, cables etc., to pass
through
c. Splicing as shown in relevant drawings
d. Smoothening of edges
e. Fixing of chequered plates by welding and/or countersunk bolts
f. Providing lifting hooks for ease of lifting.
10.19 Cutting, heating or enlarging holes may be carried out only with prior written
approval from the ENGINEER.
11.0 FIELD CONNECTIONS:
11.1 ASSEMBLY BY PERMANENT BOLTS:
11.1.1 The number of washers on permanent bolts shall not be more than two (2)
and not less than one (1) for the nuts and one (1) for the bolt head.
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11.1.1 Only wooden rams or mallet shall be used in forcing members into position
in order to protect the metal from injury or shock.
11.1.2 Where bolting is specified on the drawing, the bolts shall be tightened to the
maximum limit. The threaded portion of each bolt shall project through the
nut by at least one thread. Tapered washers shall be provided for all heads
and nuts to achieve uniform bearing on sloping surface.
11.1.3 To prevent loosening of nuts, spring washers or lock-nuts shall be provided
as specified in the design / shop drawings.
11.1.4 All machine fitted bolts shall be perfectly tight and the ends shall be checked
to prevent nuts from becoming loose. No unfilled holes shall be left in any
part of the structure.
11.2 ASSEMBLY BY WELDING:
11.2.1 All field assembly by welding shall be executed in accordance with the
requirements for shop fabrication. Where the steel has been delivered
painted, the paint shall be removed before field welding for a distance of at
least 50 mm on either side of the joints to be welded.
11.2.2 All other requirements of welding and its acceptance standards shall be in
accordance with clauses specified in TCE.M4-405-01(Supply and
Fabrication of structural steel).
11.3 ASSEMBLY BY HIGH STRENGTH FRICTION GRIP BOLTS (HSFG
BOLTS)
11.3.1 Assembly of structures with HSFG bolts shall conform to IS:4000
11.3.2 The mating surface shall be prepared in accordance with the requirements
of design in order to achieve required properties to develop adequate friction
between the surfaces.
11.3.3 The mating surfaces shall be absolutely free from grease, Lubricant, dust,
rust etc., and shall be thoroughly cleaned before assembly.
11.3.4 The nuts shall be tightened up to the specific torque with the help of torque-
wrench or by half-turn method with the help of pneumatic wrench lever.
11.3.5 The direction of tightening of the nuts shall be from the middle towards the
periphery of assembly.
11.3.6 After desired tightening the bolt heads, nuts and edges of the mating
surfaces shall be sealed with a coat of paint to obviate entry of moisture.
12 INSPECTION
ENGINEER/OWNER or their authorised representatives shall have free
access to all parts of the job during erection and all erection shall be
subjected to their approval. In case of faulty erection, all dismantling and re-
erection required will be at CONTRACTOR's cost. No paint shall be applied
to rivet heads or field welds or bolts until these have been approved by
ENGINEER.
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TCE.M4-405-02
13 TOLERANCES
Tolerances mentioned below shall be achieved after the entire structure or
part thereof is in line, level and plumb. The tolerances specified below do
not apply to steel structures where the deviations from true position are
intimately linked with and directly influence technological process. In such
cases, the tolerances on erected steel structures shall be as per
recommendations of process technologists/suppliers which will be indicated
in the drawings.
13.1 COLUMNS
13.1.1 Deviation of column axes at foundation top level with respect to true axes
(a) In longitudinal direction : ± 5 mm

(b) In lateral direction : ± 5 mm
13.1.2 Deviation in the level of bearing surface of
columns at foundation top with respect to true ± 5 mm
level
13.1.3 Out of plumbness (verticality) of column axis
from true vertical axis, as measured at
column top :
± 1/1000 of column height
For columns up to and including15
(a) in mm or ±15mm
meters in height
whichever is less
± 1/1000 of column height
For columns exceeding 15 meters
(b) in mm or ± 20 mm
in height
whichever is less
13.1.4 Deviation in straightness in longitudinal and ± 1/1000 of column height
transverse planes of column at any point in mm or ± 10 mm
along the height whichever is less
13.1.5 Difference in erected position of adjacent
pairs of columns along length or across
width of building prior to connecting width of ± 5 mm
building prior to connecting trusses/beams
with respect to true distance
13.1.6 Deviation in any bearing or seating level
± 5 mm
with respect to true level
13.1.7 Deviation in differences in bearing levels of
a member on adjacent pair of columns both ± 5 mm
across and along the building
13.2 TRUSSES AND BEAMS
13.2.1 Shift at the centre of span of top chord ± 1/250 of height of truss in
member with respect to the vertical plane mm or ± 15 mm whichever is
passing through the centre of bottom chord less
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13.2.2 Lateral shift of top chord of truss at the

centre of span from the vertical plane ± 1/1500 of span of truss in
whichever passing through the centre of mm or ± 10 mm is less
supports of the truss
13.2.3 Lateral shift in location of truss from its true
± 10 mm
vertical position
13.2.4 Lateral shift in location of purlin true position ± 5 mm
13.2.5 Deviation in difference of bearing levels of i) ±1/1200 of span or ± 20
trusses or beams from the true difference mm for trusses
ii) For beams :
Depth < 1800mm : ±6mm
Depth > 1800mm : ±10 mm
13.2.6 Deviation in sag in chords and diagonals of 1/1000 of length in mm
truss between node points or10mm whichever is
smaller
13.2.7 Deviation in sweep of trusses, beams etc in 1/1000 of span in mm
the horizontal plane subject to a maximum of 10
mm
13.3 CRANE GIRDERS & RAILS
Shift in the centre line of crane rail with
13.3.1 ± (web thickness /2 + 2 mm)
respect to centre line of web of crane girder
Shift in plan of alignment of crane rail with
13.3.2 ± 5 mm
respect to true axis of crane rail at any point
Difference in alignment of crane rail in plan
13.3.3 measured between any two points 2 meters ± 1 mm
apart along rail
Deviation in crane track with respect to time
13.3.4
gauge
For track gauges up to and
(a) ± 5 mm
including 15 meters
± [5 + 0.25 (S-15)] where S
For track gauges more than 15
(b) in meters is true gauge,
meters
subject maximum of ±10mm.
Deviation in the crane rail level at any 1/1200 of the gauge or ±
13.3.5
distance point from true level 10mm whichever is less
Difference in the crane rail actual levels
13.3.6 between any two points 2 meters apart ± 2 mm
along the rail length
Difference in levels between crane track
13.3.7
rails at
(a) Supports of crane girders ± 15 mm
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2 mm subject to grinding of
Relative shift of crane rail surfaces at a joint
13.3.8 surfaces for smooth
in plan and elevation
transition.
Relative shift in the location of crane stops 1/1000 of track gauge S in
13.3.9 (end buffers) along the crane tracks with mm subject to maximum of
track gauge S in mm 20 mm
13.4 CHIMNEYS AND TOWERS
Out of plumbness (verticality) from the true 1/1000 of the height of the
13.4.1
vertical axis chimney or tower in mm
13.5 BUNKERS
Deviation in length of bunker from true
13.5.1 ± 1/1000 of length in mm
length
13.5.2 Deviation in width of bunker from true width ± 1/1000 of width in mm
Deviation in height of bunker from true
13.5.3 ± 1/500 of height in mm
height
Deviation in diagonal length in any
± 1/500 of diagonal length in
13.5.4 horizontal cross section from the true
mm
diagonal length
14 PAINTING
14.1 After steel has been erected, all bare and abraded spots, field welds, bolt
heads and nuts shall be spot painted. Before paint is applied, the surface
shall be dry and free from dust, dirt, scale and grease. Surface preparation
and painting of steel surfaces shall be in accordance with painting
specification.
15 SAFETY
15.1 GENERAL REQUIREMENTS:
The Following general safety aspects shall be ensured by the
CONTRACTOR at his cost in addition requirements of IS800 section 17:-
a) As per Safety, Health and Environment (SHE) Plan all staff members
and workers are required to under-go medical check-up prior to their
induction to the plant to ensure fitness.
b) Ensure that all the workmen & supervisory staff engaged on the job are
authorised category wise by the competent authority.
c) Ensure that the persons to be deployed for working at height have
undergone height phobia check and are declared fit by Registered
Medical Practitioner.
d) Ensure that all the persons have undergone Safety Induction Training.
e) Ensure usage of personnel protective equipment / clothing by all as per
job requirement.
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chequered plates, proper toe guards, hand railing and minimum two
access / approach ladders, provision of lifeline where anchoring of
safety belts to permanent nearby structures is not feasible, fall arrestors,
safety nets etc. for working at height.
g) Ensure full compliance to the general safety requirement specified in
"Safety Manual” .
h) Ensure that workmen are briefed about the hazards involved and
precautions to be taken i.e. tool box talks are conducted.
i) Ensure the worthiness of all construction equipment, hand tools, power
tools, hardware, and all lifting tackles i.e. these are tested and certified
and the latest valid load test certificates are available for safe working
load by Government approved Competent Authority. The physical
condition certificate from Government approved Competent Authority
should also be available.
j) Ensure that all electrical installations have proper earthing of all non-
current carrying parts.
k) Ensure that all electrical installations are having devices like earth
leakage current breaker (ELCB) for cutting off the power supply in the
event of any leakage.
l) Ensure that all electrical power hand tools are regularly checked and
are equipped with Safety Guard to isolate moving parts and also to
inspect and ensure that the handles are having proper insulation without
any damage whatsoever.
m) Ensure that storage, handling and usage of Oxy – acetylene gas
cylinders are strictly as per safety requirements like; the Cylinders are
in trolleys duly chained and in upright condition, only regular keys,
handles and spanners are used for operating valves, regulators etc.,
that hood / canopy is provided and regular lighters are only used for
initial ignition.
n) Ensure no lifting Ropes are near electrical equipment or electrical wire.
The lifting ropes should be free from any contact of electrical
applications.
15.2 SPECIFIC REQUIREMENTS:
The following specific safety requirements shall be ensured by
CONTRACTOR at his cost:-
a) Ensure that complete methodology to the last details of assembly and
erection at site is prepared in advance, submitted for review and
approved by ENGINEER before start of erection.
b) Ensure that proper relevant work permit is obtained for working in
operational area.
c) Ensure 100 % supervision by competent & experienced Supervisor,
Engineer & Safety Officer.
d) Ensure that working at height is limited to daylight only.
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board’s / placards for the purpose. Where required proper

announcements shall be made.
f) Ensure use of proper tools only. While working at height all the hand
tools shall be tied with adequate size of nylon rope to the body of the
worker / nearest permanent structure / hand railing to avoid the tool from
falling down accidently and hitting any person working below.
16 METHOD OF MEASUREMENT
16.1 For the purpose of payment, the weight of the actual, completed structures
shall be calculated from the approved fabrication drawings for different items
of work. CONTRACTOR shall submit to OWNER relevant material list
containing weight of each item.
16.2 No allowance will be permitted for weights of erection bolts, washers, screws
etc. in calculating the weight of the completed structure. No allowances will
be permitted for galvanizing, welding or for rolling margins. In the case of
field connection with bolts, the bolts along with nuts and washer will be
considered for payment against appropriate item in the schedule of prices.
One tonne for the purpose of payment shall mean ONE METRIC TONNE
i.e. 1000 Kg.
16.3 The weight of a member made out of standard rolled sections such as
beams, channels, angles, etc. shall be based on the weight of the member
given in IS 808, without deducting for holes, notches, bevel cuts, etc. Where
a component consists of a cut joist or channel, the full weight of the rolled
section shall be considered only if more than half the depth of the section is
used. Otherwise only half the section unit weight shall be taken. Deductions
shall be made in the weight of gussets/plates including chequered plates for
skew cuts, notches and openings of 900 sq.cm. or larger.
16.4 For gussets/plates used in trusses, bracings, columns, beams etc. the area
shall be that of the minimum circumscribing rectangle..
16.5 The weight of any built-up member shall be separated into the weight of each
component.
16.6 Erection bolts installed by erector shall be left in position on completion of
erection; however, no additional payment shall be made either for supply or
use of such bolts. If erection bolts are removed after erection is complete,
holes shall be plug welded and ground smooth. No extra payment shall be
made for such plug welding. Unit weight shall be as per 78.5kN/m3.
17 CLEAN UP OF WORK SITE
During erection, the CONTRACTOR shall without any additional payment,
at all times keep the working and storage areas used by him, free from
accumulation of waste materials or rubbish. Before completion of erection,
he shall remove or dispose of in a satisfactory manner all temporary
structures, waste and debris and leave the premises in a condition
satisfactory to OWNER/ENGINEER.
-END-
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TCE.M4-405-04
SPECIFICATION FOR
SHEET 1 OF 16
PAINTING OF STRUCTURAL STEEL
1.0 SCOPE
1.1. This specification covers the general requirements of materials, surface preparation,
application method, quality requirements and measurement requirements for shop and
field painting for Structural Steel works using hot/ cold rolled steel sections and tubular
members joined by using bolting and/ or welding. The term painting covers all types of
organic and inorganic coating for anti-corrosive protection of steel structures and
including floor plates.
1.2. Surfaces considered for paint application refer to carbon steel surfaces subjected to
atmospheric exposure or exposure to corrosive environment. Paint is to be applied
after specified surface treatment has been carried out. Steel surfaces in bond with
concrete shall not be painted.
1.3. Paint application shall ensure continuous adherent organic/ inorganic coating film of
specified thickness on the prepared surface to protect it from exposure to environment.
1.4. The scope of works covered under this specification are;

i. Supply of all equipment and material for surface preparation, primers, paints and
all other materials required for painting other than Owner's supply.
ii. Furnishing of all labour, materials, tools & equipment and the performance of all
operations and incidentals necessary for surface preparation, painting, handling,
storing, transporting, scaffolding etc.
iii. Testing of paints as per the relevant codes/ contract specifications, in the paint
manufacturers laboratory, making arrangements for OWNER to witness the tests
and furnishing of required test certificates for Owner’s approval.
iv. Testing of paints as per the relevant codes/ contract specifications, in the Standard
Laboratory identified by the Owner and furnishing of required test certificates for
Owner’s approval.
v. Repair work of damaged / pre-erection / fabrication shop primer and weld joints at
field.
vi. Inspection of painting system after its application to conform to the specification
requirement.
vii. Any other requirement as required for satisfactory completion of specified work.
1.5. Reference shall be made to TABLE - 1 for paint types and TABLE - 2 for the paint
systems covered in the scope of works.
submitted herewith. In consideration of receipt of this document; unless agreed to in contrary in the Contract; the recipient agrees to maintain such information in confidence and to not reproduce or otherwis e
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TCE.M4-405-04
SPECIFICATION FOR
SHEET 2 OF 16
2.0 EXCLUSIONS
This specification shall cover all structural steel section either rolled, fabricated or
structural tubes and hollow sections. It excludes paintings of the following structures
/equipment.
i. Mechanical & electrical equipment and parts.
ii. Technological Structures
iii. Buried & Overhead piping works
iv. Storage tanks
v. Insulated parts
vi. Interior surfaces of structural tubes and hollow sections
vii. Electroplating of steel surfaces
viii. Any other items of work specifically excluded in the scope of works.
3.0 APPLICABLE CODES, STANDARDS
The pertinent clauses of the following Indian / International Codes, Standards and
Specification (latest editions including all applicable official amendments,
reaffirmations and revisions) shall apply to the material and workmanship covered by
this specification. In the event of the conflict of certain requirements between this
specification and the codes referred herein, this specification shall govern.
It is not the intent to specify herein all the codes and standards required for the
satisfactory completion of work. The list of codes and standards indicates certain
primary codes & standards and not all the codes required for the work under the
contract. It is understood that all the pertinent codes and standards shall form the part
of this specification whether explicitly indicated or not.
The codes and standards shall be latest as on the day of award of contract of the works
unless otherwise specified. Contractor shall be responsible to inform to the Consultant/
Owner in case of any revisions/re-affirm/amendment in the relevant codes and
standards after the date of award of contract within 30 days of the issue of such
revision/re-affirm/amendment of the code/ standard. Consultant/ Owner may approve
use of the earlier code/ standard if the revisions do not materially affect the statutory
requirements of the project or does not impact safety practices. Any cost impact arising
out of such revisions shall be mutually agreed.
3.1 Indian Standard Codes
1. IS 5: 2007 Colours for ready mixed paints and enamels

(Reaffirmed 2017)
2. IS:101 Methods of sampling and test for paints, varnishes

and related products (all parts & all sections).
3. IS 104: 2017 Specification for Ready mixed paint, brushing, zinc

chrome, priming
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TCE.M4-405-04
SPECIFICATION FOR
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4. IS 158: 2015 Ready Mixed paint, Brushing, Bituminous, Black,

Lead free, Acid, Alkali and heat resisting.
5. IS 1303: 1983 Glossary of Terms relating to paints

(Reaffirmed 2017)
6. IS: 9954-1981 Pictorial Surface Preparation Standards for Painting

of Steel Surfaces.
(Reaffirmed 2015)
7. IS:13183-1991 Aluminium paint, Heat resistant-specification.

(Reaffirmed 2015)
IS 800: 2007
10. General Construction in Steel –Code of Practice
(Reaffirmed 2017)
3.2 International Standard Codes

i. SSPC Society for Protective Coatings (USA) Volume I & II
ii. SA Swedish Standards SIS 055900
iii. NACE National Association of Corrosion Engineers, USA
(NACE)
iv. ISO 4624: 2016 Paints and Varnishes – Pull off test for adhesion
v. ISO 8501-1-2007 Preparation of Steel Substrates before application
ISO 8501-2-1994 of paints and related products. Visual assessment
ISO 8501-3-2007 of surface cleanliness. (Parts 1, 2 & 3)
vi. ISO 8502
Preparation of Steel Substrates before application
Part-2:2017, of paints and related products-Tests for
Part-3:2017, assessment of surface cleanliness.(Parts 2-4)
Part-4: 2017
vii. ISO 8503-2012 Preparation of Steel Substrates before application
of paints and related products-Surface roughness
characteristics of blast-cleaned steel substrates.
Part 1& 2
viii. ISO 8504 Preparation of Steel Substrates before application
Part-1:2019 of paints and related products-Surface preparation
Part-2:2019 methods Part 1-3
Part-3:2018
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SPECIFICATION FOR
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ix. ISO 12944-Part 5 Paints & Varnishes-Corrosion Protection of Steel

2019 Structures by Protective Paint System
4.0 HEALTH, SAFETY AND REGULATORY REQUIREMENTS
4.1 The work covered in this specification, shall comply with all relevant government and
local laws, regulations and standards. For subjects not covered by regulations, codes,
standards or specifications, the materials and construction shall be based on good
engineering practice, subject to approval by Owner. Contractor shall submit Material
Safety Data Sheet (MSDS) of all materials proposed to be used in the project.
4.2 CONTRACTOR shall ensure that all health and safety regulations are adopted for the
erection of scaffolding and use of the selected paint material.
4.3 All necessary precautions shall be taken to ensure the safety of personal and property.
Extreme caution shall be used when working with oil or oil-based paints, cleaning fluids
etc., especially near oxygen piping or oxygen equipment. Heavy concentrations of
volatile or toxic fumes must be avoided and in confined areas, blowers or exhaust fans
shall be used.
4.4 The instructions of the paint manufacturer shall be followed regarding storage, surface
preparation, mixing and thinning of paints, paint application, timing between coats and
safety instructions.
4.5 Rags and other waste material soiled with paints, thinners or solvents shall be kept in
tightly closed metal containers while on the jobsite and when not in use. Legal disposal
of waste materials outside plant site premises is Contractor’s responsibility.
4.6 Lead being hazardous material it is recommended to use lead free paint as per
requirement of clause 3.6 of IS158.
5.0 SURFACE PREPARATION OF STEEL

All surfaces shall be cleaned of loose substances and foreign materials (viz. dirt, rust,
scale, oil, grease, welding slag) and given a regular profile to rigidly anchor the primer
coat on the substrate.
One or more of the following methods of surface preparation shall be followed,

depending on condition of steel surface and as specified in the data sheet. ENGINEER
reserves the right to instruct the type of surface preparation depending upon the
condition of material. The following table indicates the types of surface cleaning
methods in order of decreasing effectiveness:
Sl. Cleaning method Specification

No. NACE SSPC ISO
1. White metal blast (Blast cleaning to #1 SP 5 8501-1 SA 3
visually clean steel)
2. Near-white metal blast (Very #2 SP 10 8501-1 SA 2.5
thorough blast cleaning)
3. Industrial blast cleaning #8 SP 14
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TCE.M4-405-04
SPECIFICATION FOR
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3. Commercial blast cleaning #3 SP 6 8501-1 SA 2

(Thorough blast cleaning)
3. Acid pickling SP 8
4. Brush blast (Light blast cleaning) #4 SP 7 8501-1 SA 1
5. Flame clean and power sanding SP 4
6. Power tool cleaning SP 3 St-3
7. Chip and hand wire brush SP 2 St-2
8. Solvent type SP 1 8504
Recommended methods of surface preparation of steel briefly are as under.

a) Solvent Cleaning.
b) Manual or hand tool cleaning.
c) Mechanical or power tool cleaning.
d) Abrasive Blast cleaning.
It is necessary that the CONTRACTOR shall have to resort to any one or combination
of the above methods of surface preparation to achieve the required acceptable
standard. Hence the rate quoted shall take into account for such preparation.
5.1 SOLVENT CLEANING
Removal of all contaminants like oil, grease, dirt, old paint shall be carried out either
by special solvents or by degreasing agents. The surface can be solvent cleaned by
methods like wiping the surface, immersing in bath, applying spray or contact with
vapours of solvents. Washing with emulsions or alkaline solutions or chemical paint
strippers may also be used. Application and cleaning of solvents shall be as per
manufacturer’s instructions and shall be in accordance with SSPC-SP1. Solvent
cleaning will not remove rust, mill scale or welding slag.
Hydrocarbon solvents will not remove corrosive chloride and sulphate salts. Hence
solvent cleaning should be followed up with other cleaning procedures before paint
application.
5.2 MANUAL OR HAND TOOL CLEANING

This method of cleaning shall be used to remove all loose mill scale, loose rust, loose
paint and other loose detrimental foreign matter by use of non-powered hand tools.
This method is applied after removal of oil and grease by solvent cleaning and chipping
and scraping to remove loose rust and scales. The surface is cleaned by vigorous wire
brushing. The minimum acceptable standards in case of manual or hand tool cleaning
shall be in accordance with ISO 8501- St2 / SSPC-SP2.
In welded construction, the welding flux, slag and fume deposit should be cleaned to
the maximum extent possible by blast cleaning, washing with water, phosphate
rinsing or power tool cleaning before wire brushing is to be undertaken. This method
will not remove rust or firmly adherent mill-scales.
5.3 MECHANICAL OR POWER TOOL CLEANING

This method of cleaning shall be used to remove all mill scale, rust, paint and other
detrimental foreign matter by use of power assisted or pneumatic hand tools like
brushes, sanding machines, sanding discs, abrasive grinders, chipping hammers,
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SPECIFICATION FOR
SHEET 6 OF 16
descalers, needle guns and rotary descalers. The method is applied after cleaning of
oil and grease by solvent cleaning and removal of loose rust by hand tool cleaning.
The minimum acceptable standards in case of power tool cleaning shall be in
accordance with ISO 8501- St3 / SSPC-SP3.
The tools shall be used carefully to avoid formation of edges and burrs, excessive
roughening of surface and burnishing to smooth slick surface. This method will not
remove rust or firmly adherent mill-scales.
5.4 ABRASIVE BLAST CLEANING (SHOT BLASTING / GRIT BLASTING)

5.4.1 Shot / Grit blasting shall be resorted to only after removal of grease, oil and other
contaminants as per SP-1and surface scale removal by hand/ power tool cleaning. The
surface cleaning is achieved by impingement of abrasive materials like graded sand or
grit of iron or synthetic materials at high velocity created by blast of clean and dry
compressed air. Blast cleaning will remove both loose and adherent materials from the
surface. Special care shall be taken on weld areas to remove flux and spatter.
Precautions shall be taken during grit or shot blasting of light gauge steel surfaces to
ensure that buckling does not occur due to continuous impingement of grit or steel
shots under high velocity. Surface anchor profiles shall be measured by Testex tape –
press-o-film.
5.4.2 Blast cleaning shall not be performed where dust can contaminate surfaces undergoing
such cleaning or during humid weather conditions having humidity exceeding 85%.
5.5 TESTS ON SURFACE PREPARATIONS
The following inspection and tests shall be performed on the steel surfaces subjected
to surface preparation. Test / inspection reports shall be submitted to ENGINEER for
his approval and acceptance.
i. Visual examination of surface preparation with comparators- SSPC- Vis-1.
ii. Profile check of the prepared surface with suitable “profilometer “eg. TESTEX
method.
iii. Dust test on blasted surfaces.
iv. Salt contamination test on blasted surfaces.
6.0 PAINT MATERIAL

The painting materials shall be selected to provide long lasting anti-corrosive surface
protection. The painting system is classified under:
Primer paints (P) to be applied on dry, clean surfaces;
Intermediate paints (I) with micaceous iron oxide (MIO) applied over prime coats as
intermediate layer to provide protection to prime coats;
Finish top coat (F) applied over prime or intermediate coats after proper cleaning and
touch up.
6.1 PROCUREMENT
All types of paints required for the work shall be as per the requirement of relevant
codes and procured from reputed manufacturers. Contractor shall obtain the detailed
list of approved paint manufacturers from the ENGINEER before initiating the
procurement action. The contractor shall also provide technical data sheet, material
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SPECIFICATION FOR
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safety data sheet and test reports from manufacturer for the specific paints to be
selected. The data sheet shall indicate relevant standards, composition in weight per
cent of pigments, VOC, additives, drying time, viscosity, spreading rate, flash point,
method of application, quality of surface preparation required, corrosion resistance
properties and colour.
6.2 STORAGE
The Paint material shall be stored strictly in accordance with the instructions of the
paint manufacturer. In general painting materials should be stored in dry, cool, well
ventilated and frost-free area and free from source of electrical sparks. Containers at
time of use shall have legible labels showing paint identification, manufacturing date,
batch number, order number and special instructions. Containers shall only be opened
at the time of use. Paints which have livered, gelled or otherwise deteriorated during
storage shall not be used. Paints that have crossed the shelf life should not be used
without inspection and approval by Owner.
6.3 PACKING
All paints delivered to the fabrication shop / site shall be in original sealed container,
as packed by the manufacturer. Paint containers shall clearly be marked with paint
manufacturer’s name, batch number, date of manufacture, shelf life and a clear
indication of the type and colour of the product.
6.4 MIXING
Paint shall be thoroughly mixed prior to application. Mixing shall be done in a well-
ventilated, clean and dust -free area. Paint shall be mixed by non-sparking, low speed
paint mixer or rolling rigs except for containers smaller than 20 litres, until a uniform
consistency is achieved as recommended by manufacturer. Mixing by air bubbling is
not permitted.
Multiple pack paint materials shall be mixed in accordance with and under the
conditions as specified by the paint manufacturer. Pot life as specified by the paint
manufacturer shall be strictly followed.
6.5 THINNER AND SOLVENTS

6.6 Only additives, thinners, solvent etc., as recommended by the paint manufacturer shall
be used only during the mixing process. A possible extension of the “pot life” by addition
of thinners is prohibited.
6.7 TESTS ON PAINT

To ensure that the supplied paint meets the stipulations, samples of paint from each
batch shall be tested in manufacturers laboratories to establish quality of paint with
respect to
i. Spread/ coverage rate
ii. Adhesion/ bond of paint to steel surfaces as per ASTM D3359.
iii. Pull off test
iv. Impact resistance test
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v. Adhesion / simulated salt spray test.

vi. Chemical analysis (Volume of solids in percentage)
vii. Abrasion resistance test
viii. Flash point
ix. Drying time
Contractor shall facilitate Owner to attend these tests in Manufacturers laboratories if
Owner wishes to attend the tests. Manufacturer’s test certificates shall be furnished for
each batch of paint by the Painting CONTRACTOR in respect of above tests for
ENGINEER’s approval and acceptance.
Engineer reserves the right to request CONTRACTOR for the following tests to be
carried out on samples of paint from standard laboratories identified by Owner.
Engineer reserves the right to test the paint material either before the commencement
of work or during the progress of work; if in his opinion the paints supplied are of inferior
quality and does not meet the code requirements.
i. Pull off test as per IS 101 Part 5 Sec 2: 1988 (R2019)
ii. Abrasion resistance test as per IS 101 Part 5 Sec 2: 1988 (R2019)
iii. Impact resistance test as per IS 101 Part 5 Sec 3: 2019
6.8 PAINT SAMPLE

Before buying the paint in bulk, it is recommended to obtain sample of paint and
establish “Control Area of Painting”. On control area; surface preparation, painting shall
be carried out in the presence of Engineer and the Manufacturer of paint.
6.9 FINISHING PAINT

Colour /Shade of the finishing paint shall be as per the choice of the Owner and
Contractor shall obtain prior approval before procurement action is initiated.
7.0 PAINT APPLICATION

Painting shall be carried out at shop/ site as per requirements of the tender. Painting
shall be carried out by any one or a combination of the following methods of application
to suit the site condition and the type of paint being used. Manufacturer’s
recommended method of application shall be strictly followed.
i. Brush Application.
ii. Roller Application.
iii. Spray Application.
7.1 BRUSH APPLICATION

Brush application of paint shall be in accordance with the following.
i. Brushes shall be of a style and quality that will enable proper application of
paint
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ii. Round, Oval (IS:487) or Wide flat brushes (IS:384) shall be used depending
upon the surface irregularity, rough or pitted steel, large flat painting areas etc.
Width of brushes shall not in general exceed 125mm.
iii. Short strokes shall be used for paint application depositing uniform amount in
each stroke and the paint brushed into all surface irregularities, crevices,
corners. This shall be followed by long and light strokes at right angles to first
coat.
iv. There shall be a minimum of brush marks left in the applied paint.
v. Brush painting shall be done for edges, corners and weld joints as a stipe coat.
vi. Surfaces not accessible to brushes shall be painted by spray.
7.2 ROLLER APPLICATION
Roller coat will be used only when specifically authorised. Suitable rollers of different
nap length to suit varying surface roughness shall be used. Rollers are not generally
recommended for application of primers. Roller application shall only be used if the
first or priming coat of paint has been applied by brush or other means. Manufacturer’s
recommendation shall be strictly followed for roller applied paints.
7.3 SPRAY APPLICATION
7.3.1 Airless or pneumatic/ Air- spray application shall be in accordance with the following
i. Airless spray application shall be as per steel structure paint Manual Vol 1 &Vol 2
SSPC, USA.
ii. Spraying shall be carried out keeping the spray gun at the minimum suitable
distance from the work piece and consistently at 90 0 to the surface being painted.
iii. Correct spray tips, air pressures etc., as recommended by the equipment supplier
shall be adopted.
7.3.2 Air spray application shall be in accordance with the following:
i. The equipment used shall be suitable for the intended purpose, shall be capable
of properly atomizing the paint to be applied, and shall be equipped with suitable
pressure regulators and gauges.
ii. Appropriate pressure and nozzles shall be those recommended by the
manufacturer of the equipment for the material being sprayed. The equipment shall
be kept in satisfactory condition to permit proper paint application.
iii. Correct combination of air volume, air pressure and fluid flow to give good
atomization shall be ensured to get a defect free painted surface.
iv. Traps or separators shall be provided to remove oil and condensed water from the
air. These traps or separators must be of adequate size and must be drained
periodically during operations. The air from the spray gun impinging against the
surface shall show no condensed water or oil.
v. Ingredients shall be kept properly mixed in the spray pots or containers during
application by continuous mechanical agitation.
vi. Spray equipment shall be kept sufficiently clean so that dirt, dried paint and other
foreign materials are not deposited in the paint film. Any solvents left in the
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equipment shall be completely removed before applying paint to the surface being
painted.
7.3.3 Selection of type of spray application shall depend upon the type of paint coating being
used. At all times paint manufacturer’s recommendation shall be strictly followed.
8.0 COATING PROCEDURE
8.1 COMPATIBILITY
General Compatibility between primer, intermediate and top coats, as applicable for
individual painting system shall be established through the paint manufacturer
supplying the paints. Primer and finishing paint for the entire project shall be procured
from the same manufacturer. Mixing of material from different manufacturers is strictly
prohibited.
8.2 Surface shall not be coated in rain, high wind, when steel surface temperature is less
than 50 C, or when the relative humidity is greater than 85%.
8.3 Applied paint system shall be allowed to cure at ambient and surface temperatures
between 10 ° C and 60 ° C with relative humidity below 85%. All paint shall be air cured.
8.4 A suitable test area (approx.0.5 m2) shall be painted with agreed paint system. The
test area shall be fully coated with all coats of the agreed coating system using the
tools and equipment to be used for the actual coating work. The painted test area shall
be maintained for the duration of the project. Painting on test piece shall be carried out
such that all the coats shall be made visible for reference at all time.
8.5 Structural steel shall preferably have prime coat and intermediate coat applied at shop,
prime coat shall be applied immediately after surface preparation and preferably within
the time as specified elsewhere in the specification. Subsequent finish coats shall be
carried out at site after the alignment and erection is complete. Portions of structural
steel members to be embedded into the concrete shall not be painted.
8.6 Surfaces inaccessible after assembly shall receive full coating/painting system prior to
assembly.
8.7 Surfaces inaccessible after erection, including top surfaces of floor beams supporting
grating / chequered plate /RC Slabs shall receive one additional coat of finish paint
over and above the number of coats specified prior to erection.
8.8 Welding edges and joint zone shall be also shop painted except if the paint is harmful
to welding operator. In such case the zone shall be coated with epoxy based weldable
blast primer for 50mm wide patch and covered with adhesive tape before full coat of
shop paint is applied on the work piece and the tape removed.
8.9 Site paint shall be applied after assembly and erection of fabricated structures.
Defective shop coat shall be cleaned and touched up with same paint as applied in
shop. Damaged shop coat shall be repaired including paint removal, surface
preparation to St3 quality and painting to satisfaction of Engineer. The erected
structure shall then be painted with intermediate coat (if applicable) and finish coat.
8.10 Field welds and areas within 50mm of welds shall be cleaned to required surface
quality before painting. Welds shall be blast cleaned, power wire brushed, chemically
scrubbed or solvent cleaned depending on nature of weld deposits.
8.11 Each coat of paint material shall be applied as continuous film of uniform thickness;
free of holidays and pin holes. Any spot or areas missed in application shall be recoated
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and permitted to dry before the next coat is applied. Applied paint should have the
desired wet film thickness.
8.12 Each coat shall be in proper state of cure or dryness before the application of
succeeding coat. Material shall be considered dry for recoating when an additional coat
can be applied without development of any detrimental film irregularities, such as lifting
or loss of adhesion of the under coat. Manufacturer’s instruction shall be strictly
followed for intervals between successive coats.
8.13 No paint shall be force dried under conditions which will cause checking, wrinkling,
blistering and formation of pin holes or detrimentally affect the condition of the paint.
8.14 No drier shall be added to paint on the job unless specifically called for in the
manufacturer's specification for the paint.
8.15 Paint shall be protected from rain, condensation, contamination, snow and freezing
until dried to the extent practicable.
8.16 Blast cleaned surface shall be coated with one coat of primer before surface
degradation occurs but in no case later than 2hrs. Irrespective of the method of surface
preparation, the first coat of primer shall be applied not later than 2-3 hours after
preparation and on dry surface.
8.17 When the successive coat of the same colour is specified, alternate coat shall be tinted
as far as practicable; sufficient to produce enough contrast to indicate complete
coverage of the surface. The tinting material shall be compatible with the material and
not detrimental to its service life. However, it is always preferable to have multiple
colours instead of tinting.
8.18 All field welded areas on shop painted item shall be mechanically cleaned using power
tool (including the weld area proper, adjacent areas contaminated by weld spatter or
fumes and areas where existing primer, intermediate / finishing paint is burnt) so as to
expose bare metal. All areas close to welds shall then be solvent cleaned.
Subsequently, new primer and finishing coats of paint shall be applied as per painting
specification.
8.19 Care shall be taken to protect adjacent equipment, piping, structures etc., from spillage
and spatter during field painting by use of adequate temporary covers. If surfaces are
accidentally spattered or sprayed, the paint shall be immediately and thoroughly
removed. For cleaning of spillages an inert absorbent material shall be used
8.20 All structures shall receive appropriate number of primer, intermediate and finishing
coats in order to achieve overall DFT as per the drawings / specifications/ data sheets.
9.0 PAINTING SYSTEM
The types of paints to be used for primer, intermediate and finish coats are specified
in TABLE-1. The recommended painting system of all Structural Steel Works covering
surface preparation, application of Primer coats, Intermediate coats (if specified) and
Final coats to develop required minimum DFT shall be indicated separately. User shall
specify selected painting system for the various structures in Specific Technical
Requirement DATA SHEET A of tender document in prescribed format.
10.0 REPAIR OF COATED SURFACE

10.1 Wherever shop primer painting is scratched, abraded or damaged, the surfaces shall
be thoroughly cleaned using emery paper and power-driven wire brush wherever
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warranted, and touched up with corresponding primer. Touching up paint shall be

matched and blended to eliminate conspicuous marks.
10.1. If more than 30% area of the painted surface of an item requires repair, the entire
surface shall be repainted. In such an event, no extra payment will be permitted.
11.0 TEST ON SURFACE PREPARATION AND PAINTING SYSTEM
11.1 The following visual standards can be used for inspection of blast cleaned steel surface
i. White metal blast – removal of all rust, scale, paint etc. to clean white metal
with uniform grey-white appearance. Streaks and strains of rust or other
contaminants are not allowed.
ii. Near white metal – provides a surface 95% as clean white metal. Light shades
and streaks are not allowed.
iii. Commercial blast – provides a surface about 2/3rd of white metal blast with very
slight residues of rust and paint stains.
iv. Brush of blast – this involves removal of loose rust, paint, scales etc. Tightly
adherent paint, rust and scale are permitted to remain.
11.2 Following inspection and tests shall be performed during and after the application of
paint system.
i. Wet film thickness (WFT) spot checks shall be carried out during the course of
painting operation to ensure that film thickness is being maintained.
ii. Dry film thickness (DFT) check for each coat of intermediate and final coating
layers in accordance with the specification and /or paint manufacturer’s
recommendation.
iii. Porosity Check: Holiday detection test shall be carried out and all indications
shall be repaired as per approved repair procedures.
11.3 The stages of inspection shall be minimum for the following stages.
i. Surface preparation by visual inspection.
ii. Primer application.
iii. Each coat of paint by DFT measurement using non-destructive DFT instrument.
12.0 FINAL INSPECTION
12.1 As part of the Quality Assurance, a final inspection in the presence of the
representatives of OWNER and CONTRACTOR shall be conducted prior to the final
acceptance of the paintwork. Part of this final inspection checks shall be
i. Visual check of the appearance to ensure the painted surface is free from
sagging, holidays, cracking, blistering, pin holes etc.
ii. Checks on DFT’s of the total applied coating system
iii. Shade verification
iv. Holiday Testing
v. Scratch Test
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vi. Adhesion test to be tested on test panels.

12.2 As part of acceptance procedure, a report shall be prepared that shall include:
i. General:
− Names of the Painting Contractor and the responsible personal
− Scope of work
− Dates when the work was carried out.
− Copy of the work and quality plan
− Deviations from this Specification and/or the quality plan.
ii. Inspection equipment
− Type and calibration of instruments used.
iii. Surface Preparation
− Condition of surface before preparation
− Checks on the requirements as specified for cleaned surface.
iv. Coating application
− Information on coating systems being applied (i.e. product names, DFT’s)
− Checks on requirements as specified for coating application
− Check on dry film thicknesses of the total coating system applied
v. Conditions
− Checks on humidity, dew point and substrate temperature.
vi. Inspection reports
− Copy of the inspection reports of the Contractor
− Inspection from an independent third party
12.3 Frequency of testing shall be minimum as per following table:
Test Standard Frequency Acceptance
criteria
Surface ISO 8501-1 One per 10 sqm As per painting
cleanliness system selected
Surface profile ISO 8503-2 One per 10 sqm As per painting
system selected
Dust ISO 8502-3 One per 10 sqm Rating 2 or better
Adhesion ISO 4624 One pretest panel 5 MPa
per shift
Holiday detection NACE RP 0188 100% of surface Zero defect
Dry Film thickness SSPC PA-2 See below 80% < DFT <120%
of specified value
Wet film thickness ISO 2802 One per 10 sqm Consistent with
DFT requirement
DFT measurement will be through five (5) spot measurements on 4cm diameter circle
with number of tests for each 10 sqm of surface of structure:
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i. For structures with surface area less than 30 sqm, each 10 sqm shall be
measured
ii. For structures less than 100 sqm in area, three 10 sqm areas randomly
selected
iii. For structures exceeding 100 sqm in area, first 100 sqm shall be measured as
in (ii) above and one 10 sqm selected randomly for each 100 sqm increment
iv. Additional measurements required when DFT value in any 10 sqm area does
not comply requirements.
13.0 DOCUMENTATION
Contractor shall keep records and furnish the following documents to the Owner
i. A written quality plan with procedure for qualification trials and for the actual
work.
ii. Daily progress report with details of weather conditions, particular of
applications, number of coats and type of material applied, anomalies, progress
of work versus program.
iii. Results of measurement of temperatures, relative humidity, surface profile, film
thickness, holiday detection, adhesion tests with signature of appropriate
authority.
iv. Particulars of surface preparation and paint application during trials and during
the work.
v. Details of non-compliance rejects and repairs.
vi. Type of testing equipment and calibration.
vii. Code and batch numbers of paint materials used, including shelf life.
viii. Visual examination of surface preparation compared with the standards.
ix. Profile check of the prepared surface with suitable “profilometer”.
x. Dry film thickness check of intermediate and final coating layers, in accordance
with the specification and/or paint manufacturer’s recommendation
xi. Checks/ tests carried out as per clauses above.
14.0 GUARANTEE
14.1 The paint system shall provide sufficient protection of the underlying steel surface
against the attack of the environment, other than mechanical damage, chemical
spillage as result of operational activities or other unusual occurrences from the outside
caused by others.
14.2 The CONTRACTOR is fully responsible for the quality of the work and for all related
QA/QC activities as indicated in the specification.
14.3 The CONTRACTOR shall guarantee quality of their coating works for the period
specified in Data Sheet-A and for the coating condition specified therein.
14.3.1 The guarantee period starts from the date of acceptance of CONTRACTOR’s paint
work.
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14.3.2 Initial acceptance of any new coating work by OWNER will not release the
CONTRACTOR of his obligation under this section until final inspection has been
carried out and acceptance of the completed work has been agreed in writing.
14.3.3 These guarantee clauses regarding coating specifications are prevailing and
supersede the warrantee requirements in General Conditions of Contract.
15.0 MEASUREMENT
15.1 Painting work shall not be measured separately, if primer painting and/or primer and
finish painting are already included in the scope of item of structural steel works which
include supply, fabrication, painting and erection of structural steel and work is
measured on the weight basis for payment.
15.2 In cases where primer and/or finish painting work as specified is carried out on erected
structural steel executed by a different agency, the method of measurement for
painting shall be on the basis of tonnage of the steel erected. For this purpose, the
tonnage of erected steel as certified for payment to the different erection agency shall
be considered as the basis and no measurement will be carried out separately.
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TABLE - 1: PAINT MATERIALS

Type Description Air drying time DFT per Temp. Remarks
coat resistance
(micron) (Dry heat)
Primer Paints
P1 Ready mixed phenolic alkyd 1 hour (touch), 30-40 100 oC IS 2074
based red-oxide zinc chromate overnight
(hard)
P2 High build phenolic alkyd- 24 hours 60-70 100 oC
based zinc phosphate
P3 Surface tolerant high build 3 hrs (touch), 80-120 120 oC
epoxy 8 hrs (hard)
P4 Two pack High Build Surface 4 hrs (touch), 80-120 80 oC
Tolerant Epoxy cured with overnight
Polyamidomine (hard)
P5 Two pack glass flake reinforced 4 hrs (touch), 180-240 80 oC
modified Epoxy cured with overnight
Polyamine (hard)
P6 Two component inorganic Zinc 15 min (touch), 50-80 400 oC
Silicate 1.5 hrs (hard)
Intermediate Paints
I1 Single pack high build phenolic 6 hours 60-80 100 oC
modified alkyd composition (touch), 2 days
(hard)
I2 Two pack air drying high build 8 hours 80-120
epoxy with MIO (touch), 7 days
(full cure)
I3 Two component Epoxy Zinc 30 min (touch), 50-60 120 oC
Phosphate Primer cured with overnight
polyamine hardener (hard)
Finish Paints
F1 Single pack air drying high 4 hours 25-30 100 oC
gloss phenolic modified alkyd (touch), 24
synthetic enamel hours (hard)
F2 Single pack air drying high 2 hours 25-30 100 oC
gloss hard finish polyurethane (touch), 6
enamel hours (hard)
F10 Aliphatic Acrylic Polyurethane 2-4 hrs 35-50 120 oC
Finish (touch), 6-8
hrs (hard)
F11 Two pack Polyurethane enamel 2 hours 35-50 100 oC
(touch), 6
hours (hard)
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TCE.12282A-CV-
3000-3001-04 RAIN WATER DRAINAGE SHEET 1 OF 1
1. SCOPE
This section covers the drainage of rainwater in excavated areas.
Grading in the vicinity of excavation shall be such as to exclude rain /

surface water draining into excavated areas. Excavation shall be kept clean
of rain and such water as the Contractor may be using for his work by
suitably pumping out the same at no extra cost to the owner. The scheme
for pumping and discharge of such water shall be approved by the
Engineer.
Contractor shall ensure that the surface runoff outside the excavated pit
/working area shall be collected through a catch water drain excavated
around the working area and led away to a natural stream, at no extra cost
to the owner .Contractor shall maintain the catch water drains in proper
condition during the construction period at no extra cost to the owner.
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SECTION:
SPEC. NO. TATA CONSULTING ENGINEERS LIMITED
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TCE.M4-419-01
GENERAL BUILDING WORKS SHEET 1 of 174
1 SCOPE
1.1 This specification covers the general requirements for civil and architectural
works comprising of masonry, flooring, skirting, dado, plastering for wall and
ceilings, painting, doors, windows, ventilators, Builders hardware,
ironmongery, Glass and glazing, Partition works, False ceiling works, toilet
cubicles, sanitary fixtures and fittings, water proofing, Metal sheet cladding,
grills and railing works.
1.2 The works under this specification shall consist of furnishing of all tools,
plants, labour, materials, and everything necessary for execution.
2 MASONRY WORK
2.1 GENERAL
2.1.1 The works covered under this specification shall include:
2.1.2 Rubble masonry. brick masonry and concrete block masonry.
2.2 APPLICABLE CODES AND STANDARDS
IS:2117 - Guide for manufacture of hand-made common burnt-

clay building bricks
IS:1200
Method of- measurement of building and civil engineering works.
IS:1077 - Specification for common burnt clay building bricks.
IS:1124 - Method of test for determination of water absorption,

apparent specific gravity and porosity of natural
building stones.
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IS:1397 - Specification for Kraft paper.
IS:1597 - Code of practice for construction of stone masonry :

Part 1 Rubble stone masonry.
IS:2116 - Specification for sand for masonry mortars.
IS:2185 - Specification for concrete masonry units (Parts 1,2 & 3).
IS:2212 - Code of practice for brickwork.
IS:2250 - Code of practice for preparation and use of masonry

mortars.
IS:2572 - Code of practice for construction of hollow concrete

block masonry.
IS:2691 - Specification for burnt clay facing bricks.
IS:2750 - Specification for steel scaffoldings.
IS:3495 - Method of test for burnt clay building bricks Part 1 to 4.
IS:3812 - PART 1 , pulverized fuel ash — specification part 1 for

use as pozzolana in cement, cement mortar and
concrete
IS:3812 - Part 2 , pulverized fuel ash —part 2 for use as

admixture in cement mortar and concrete
IS:6041/ - Code of practice for construction of autoclaved cellular

concrete block masonry.
IS:6042
IS:13757 Burnt clay fly ash building bricks Specification
2.3 UNCOURSED RANDOM RUBBLE MASONRY, IN FOUNDATION. PLINTH

AND SUPERSTRUCTURE
2.3.1 MATERIALS
2.3.1.1 Stones for the works shall be of the type specified such as granite, trap,
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approved by Engineer. Stone shall be hard, sound, durable, fine

grained and uniform in colour (for superstructure work) and free from
weathering decay and defects like cavities, cracks, flaws, sand holes,
injurious veins, patches of loose or soft materials and other similar
defects that may adversely affect its strength and appearance. As far as
possible stones shall be of uniform colour, quality and texture.
Generally stone shall not contain crypst, crystalline silica or chart, mica
and other deleterious materials like iron-oxide, organic impurities etc.
Stones with round surface shall not be used and work shall conforming
to IS1597
2.3.1.2 The compressive strength of common types of stones shall be a

minimum of 300kg/cm2 and the percentage of water absorption shall
generally not exceed 5% as per test conducted in accordance with
IS:1124.
2.3.1.3 Cement-sand mortar for stone masonry works shall be in the proportion
of 1:6 unless otherwise specified in the respective items of work. Sand
for masonry mortar shall conform to IS:2116. The sand shall be free
from clay, shale, loam, alkali and organic matter and shall be of sound,
hard, clean and durable particles. Sand shall be approved by
ENGINEER. If so directed by the ENGINEER, sand shall be screened
and washed till it satisfies the limits of deleterious materials.
2.3.1.4 For preparing cement mortar, the ingredients shall first be mixed
thoroughly in dry condition. Water shall then be added and mixing
continued to give a uniform mix of required consistency. Mixing shall
be done thoroughly in a mechanical mixer, unless hand mixing is
specifically permitted by the ENGINEER. The mortar thus mixed shall
be used as soon as possible, preferably within 30 minutes from the time
water is added to cement. In case, the mortar has stiffened due to
evaporation of water, this may be re-tempered by adding water as
required to restore consistency, but this will be permitted only upto 30
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which is partially set shall be rejected and shall be removed forthwith

from the site. Droppings of mortar shall not be re-used under any
circumstances
2.3.1.5 The CONTRACTOR shall arrange for test on mortar samples if so

2.3.2 WORKMANSHIP
2.3.2.1 For all works below ground level the masonry shall be random rubble
un-coursed with ordinary quarry dressed stones for the hearting and
selected quarry dressed stones for the facing. Stones having sharp
corners or round surface shall not be used.
2.3.2.2 For all works above ground level and in superstructure the masonry
shall be random rubble un-coursed, well bonded, faced with hammer
dressed stones with squared quoins at corners. The bushings on the
face shall not be more than 40 mm on an exposed face and on the face
to be plastered it shall not project by more than 12 mm nor shall it have
depressions more than 10 mm from the average wall surface.
2.3.2.3 Face stones shall extend back sufficiently and bond well with the
masonry. The depth of stone from the face of the wall inwards shall not
be less than 2/3 the thickness of wall. The length of the stone shall not
exceed three times the height and the breadth on base shall not be
greater than three-fourths the thickness of wall nor less than 150 mm.
The height of stone may be upto a maximum of 300 mm. Hearting
stones shall not be less than 150 mm in any direction and shall be
bedded in mortar. Stones shall be laid with its grains horizontal.
2.3.2.4 Chips and spalls shall be used wherever necessary to avoid thick
mortar joints and to ensure that no hollow spaces are left in the
masonry. The use of chips and spalls in the hearting shall not exceed
20 percent of the quantity of stone masonry. Spalls & chips shall not be
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used on the face of the wall and below hearting stones to bring them to
the level of face stones.
2.3.2.5 The maximum thickness of joints shall not exceed 20 mm. All joints
shall be completely filled with mortar. When plastering or pointing is not
required to be done, the joints shall be struck flush and finished as the
work proceeds. Otherwise, the joints shall be raked to a minimum
depth of 20 mm by a raking tool during the progress of the work while
the mortar is still green.
2.3.2.6 Through or bond stones shall be provided in walls up to 600 mm thick

and in case of walls above 600 mm thickness, a set of two or more
bond stones overlapping each other by at least 150 mm shall be
provided in a line from face to back. In case of highly absorbent types
of stones (porous lime stone and sand stone, etc.) the bond stone shall
extend about two-thirds into the wall and a set of two or more bond
stones overlapping each other by at least 150 mm shall he provided.
Each bond stone or a set of bond stones shall be provided for every 0.5
sq.m of wall surface and shall be provided at 1500mm clear spacing in
each course.
2.3.2.7 All stones shall be sufficiently wetted before laying to prevent

absorption of water from the mortar. Stones shall be laid on their natural
bed and shall be solidly bedded full in mortar with close joints. Chips of
stone spalls be wedged into the work wherever necessary. No dry work
or hollow spaces shall be allowed and every stone whether large or
small shall be carefully selected to fit snugly the interstices between the
large stones. Masonry shall be built breaking joints in all the three
directions. Bond stone and headers shall be properly laid into the work
and shall be marked by the Contractor with white lead paint. The bond
stones shall be provided as specified in para 3.1.2.6. The masonry work
in wall shall be carried up true to plumb or to specified batter. Random
rubble masonry shall be brought to the level courses at plinth, window
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comprising of one part of mortar as used for masonry and two parts of
graded stone aggregate of 20mm nominal size. The masonry in
structure shall be carried uniformly. Where the masonry of one part is to
be delayed, the work shall be racked back at an angle not steeper than
450. Height of wall raised in any one day shall not exceed one metre.
2.3.2.8 Green work shall be protected from rain by suitable covering. Masonry
work shall be kept constantly moist on all the faces for a minimum
period of seven days for proper curing of the joints.
2.3.2.9 Double scaffolding having two sets of vertical supports shall be

provided to facilitate execution of the masonry works. The scaffolding
shall be designed adequately considering all the dead, live and possible
impact loads to ensure safety of the workmen, in accordance with the
requirements stipulated in IS:2750 and IS:3696 (Part 1). Scaffolding
shall be properly maintained during the entire period of construction.
Single scaffolding shall not be used on important works and will be
permitted only in certain cases as decided by the ENGINEER. Where
single scaffolding is adopted, only minimum number of holes, by
omitting a header shall be left in the masonry for supporting horizontal
scaffolding poles. All holes in the masonry shall be carefully made
good before plastering/painting.
2.3.2.10 CONTRACTOR shall note that the unit rates quoted for the
masonry work shall be deemed to include for the installation of
miscellaneous inserts such as pipe sleeves, bolts, steel sections with
anchors etc. and providing pockets, leaving openings, cutting chases
etc. in accordance with the construction drawings. Miscellaneous
inserts shall be either supplied FREE by the OWNER or to be furnished
by the CONTRACTOR. Any of the miscellaneous inserts which are
required to be fabricated and supplied by the CONTRACTOR and
cement concrete to be provided for fixing embedments, hold fasts of
door/window frames etc. shall however, be measured and paid
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2.3.3 MEASUREMENT
2.3.3.1 Measurement shall be in cu.m correct to two places of decimal. The

quantities measured and paid for, shall be those as actually executed
after making deductions for openings, lintels etc.
2.3.3.2 No deductions shall be made for openings less than 0.1sq.m area or for
embedments upto 0.1 sq.m in section.
2.3.3.3 Stone masonry curved in plan to a mean radius upto 6m shall be

measured and paid as curved wall as a separate item of works. Stone
masonry works curved in plan to a mean radius more than 6m shall be
measured and paid like a straight wall.
2.4 COURSED RUBBLE MASONRY (FIRST SORT) FOR SUPERSTRUCTURE
2.4.1 MATERIALS
2.4.1.1 The material specification for the work shall be as per clause 2.3.1
2.4.2 WORKMANSHIP
2.4.2.1 Face stones shall be hammer dressed on all beds, and joints so as to
give them approximately rectangular block shape. These shall be
squared on all joints and beds. The bed joint shall be rough chisel
dressed for at least 80 mm back from the face, and side joints for at
least 40 mm such that no portion of the dressed surface is more than 6
mm from a straight edge placed on it. The remaining unexposed portion
of the stone shall not project beyond the surface of bed and side joint.
The bushing on the face shall not project more than 40 mm as an
exposed face and 10 mm on a face to be plastered. The hammer
dressed stone shall also have a rough tooling for minimum width of 25
mm along the four edges of the face of the stone, when stone work is
exposed.
2.4.2.2 All stones shall be wetted before use. The walls shall be carried up truly
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horizontal and all vertical joints shall be truly vertical. The height of each
course shall not be less than 150mm or more than 300mm
2.4.2.3 Face stones shall be laid alternate headers and stretchers. No pinning
shall be allowed on the face. No face stone shall be less in breadth than
its height and at least one third of the stones shall tail into the work for
length not less than twice their height.
2.4.2.4 The hearting or the interior filling of the wall shall consist of stones
carefully laid on their proper beds in mortar; chips and spalls of stone
being used where necessary to avoid thick beds of joints of mortar and
at the same time ensuring that no hollow spaces are left anywhere in
the masonry. The chips shall not be used bellow the hearting stone to
bring these up to the level of face stones. The use of chips shall be
restricted to the filling of interstices between the adjacent stones in
hearting and these shall not exceed 10% of the quantity of stone
masonry.
2.4.2.5 The masonry in a structure shall be carried up uniformly but where

breaks are unavoidable, the joints shall be raked back at angle not
steeper than 45°. Toothing shall not be allowed.
2.4.2.6 Bond Stones shall be as specified in 3.1.2.6 except that a bond stone or
a set of bond stones shall be inserted 1.5 to 1.8 meters apart, in every
course.
2.4.2.7 The quoins shall be of the same height as the course in which these
occur. These shall be at least 450 mm long and shall be laid stretchers
and headers alternatively. These shall be laid square on the beds,
which shall be rough-chisel dressed to depth of at least 100 mm. In
case of exposed work, these stones shall have a minimum of 25 mm
wide chisel drafts at four edges, all the edges being in the same plane.
2.4.2.8 All bed joints shall be horizontal and all side joints vertical. All joints
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cm thick. When plastering or pointing is not required to be done, the

joints shall be struck flush and finished at the time of laying. Otherwise,
joints shall be raked to a minimum depth of 20 mm by raking tool during
the progress of work, when the mortar is still green.
2.4.2.9 Type of scaffolding to be used shall be as per Clause 2.3.2.9
2.4.2.10 Requirements of execution of the work and curing shall be as

stipulated in clause 2.3.2.7and clause 2.3.2.8.
2.4.2.11 Installation of miscellaneous inserts in the masonry shall be as

specified in clause 2.3.2.10
2.4.3 MEASUREMENT
2.4.3.1 Measurement shall be in cu.m correct to two places of decimal. The

quantities measured and paid for, shall be those as actually executed
after making necessary deductions for openings, lintels etc.
2.5 BRICK MASONRY WORK
2.5.1 Bricks used in the works shall conform to the requirements laid down in
IS:1077 /IS:13757. The class of the bricks shall be as specifically indicated
in the respective items of work.
2.5.2 Standard modular size of common bricks shall be 190mm x 90mm x 90mm
as per IS:1077/ IS13757. The nominal thickness of one brick and half brick
walls using modular bricks shall be considered as 200 mm and 100 mm
respectively. In the event of use of non-modular bricks, standard size shall
be 230mm x ll0mm x 70mm. The nominal thickness of one brick and half
brick walls using non-modular bricks shall be considered as 230 mm and
115 mm respectively. The dimensional tolerances of modular and non-
modular sized bricks over the standard sizes shall be as per IS 1077. /
IS13757.
2.5.3 Normal Clay Bricks shall be sound, hard, and homogenous in texture, well
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or copper coloured, of regular shape and size & shall have sharp and
square edges with smooth rectangular faces. The bricks shall be free from
pores, cracks, flaws and nodules of free lime. Hand moulded bricks shall
be moulded with a frog and those made by extrusion process may not be
provided with a frog. Bricks shall give a clear ringing sound when struck
and shall have a minimum crushing strength of 5N/sq.mm unless otherwise
specified in the item.
2.5.4 Clay Fly ash bricks shall be hand/machine moulded and shall be made from
the admixture of suitable soils and fly ash in optimum proportioned as per
IS2117. Fly ash used for manufacture of bricks shall conforming to grade 1
or grade 2 as per IS3812. The bricks shall be free from pores, cracks, flaws
and nodules of free lime. Hand moulded bricks shall be moulded with a
frog and those made by extrusion process may not be provided with a frog.
Bricks shall give a clear ringing sound when struck and shall have a
minimum crushing strength of 5N/sq.mm unless otherwise specified in the
item.
2.5.5 The average water absorption shall not be more than 20 percentages by
weight up to class 12.5 and 15 percentages by weight for higher classes.
Bricks which do not conform to this requirement shall be rejected. Over or
under burnt bricks are not acceptable for use in the works.
2.5.6 Sample bricks shall be submitted to the ENGINEER for approval and bricks
supplied shall conform to approved samples. If demanded by ENGINEER,
brick samples shall be got tested as per IS: 3495 by CONTRACTOR at no
extra cost to OWNER. Bricks rejected by ENGINEER shall be removed
from the site of works within 24 hours.
2.5.7 Mortar for brick masonry shall consist of cement and sand and shall be
prepared as per IS:2250. Mix shall be in the proportion of 1:5 for all
brickworks, unless otherwise specified in the respective items of work.
Sand for masonry mortar shall conform to IS:2116. The sand shall be free
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If so directed by the ENGINEER, sand shall be screened and washed till it

satisfies the limits of deleterious materials.
2.5.8 For preparing cement mortar, the ingredients shall first be mixed thoroughly
in dry condition. Water shall then be added and mixing continued to give a
uniform mix of required consistency. Mixing shall be done thoroughly in a
mechanical mixer, unless hand mixing is specifically permitted by the
ENGINEER. The mortar thus mixed shall be used as soon as possible,
preferably within 30 minutes from the time water is added to cement. In
case, the mortar has stiffened due to evaporation of water, this may be re-
tempered by adding water as required to restore consistency, but this will
be permitted only upto 30 minutes from the time of initial mixing of water to
cement. Any mortar which is partially set shall be rejected and shall be
removed forthwith from the site. Droppings of mortar shall not be re-used
under any circumstances.
2.5.9 The CONTRACTOR shall arrange for test on mortar samples if so directed
by the ENGINEER.
2.5.10 WORKMANSHIP
2.5.10.1 Workmanship of brick work shall conform to IS: 2212. All bricks
shall be thoroughly soaked in clean water for at least one hour
immediately before being laid. The cement mortar for brick masonry
work shall be as specified in the respective item of work. Brick work
200mm/230mm thick and over shall be laid in English Bond unless
otherwise specified. 100mm/115mm thick brickwork shall be laid with
stretchers. For laying bricks, a layer of mortar shall be spread over the
full width of suitable length of the lower course. Each brick shall be
slightly pressed into the mortar and shoved into final position so as to
embed the brick fully in mortar. Only full size bricks shall be used for
the works and cut bricks utilised only to make up required wall length or
for bonding. Bricks shall be laid with frogs uppermost.
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2.5.10.2 All brickwork shall be plumb, square and true to dimensions

shown. Vertical joints in alternate courses shall come directly one over
the other and be in line. Horizontal courses shall be levelled. The
thickness of brick courses shall be kept uniform. In case of one brick
thick or half brick thick wall, at least one face should be kept smooth
and plane, even if the other is slightly rough due to variation in size of
bricks. For walls of thickness greater than one brick both faces shall be
kept smooth and plane. All interconnected brickwork shall be carried
out at nearly one level so that there is uniform distribution of pressure
on the supporting structure and no portion of the work shall be left more
than one course lower than the adjacent work. Where this is not
possible, the work shall be raked back according to bond (and not saw
toothed) at an angle not exceeding 45 0. But in no case the level
difference between adjoining walls shall exceed one metre. Brick-work
shall not be raised more than one metre per day.
2.5.10.3 Bricks shall be so laid that all joints are well filled with mortar. The
thickness of joints shall not be less than 6 mm and not more than 10
mm. The face joints shall be raked to a minimum depth of 10mm/15mm
by raking tools during the progress of work when the mortar is still
green, so as to provide a proper key for the plastering/pointing
respectively to be done later. When plastering or pointing is not
required to be done, the joints shall be uniform in thickness and be
struck flush and finished at the time of laying. The face of brickwork
shall be cleaned daily and all mortar droppings removed. The surface
of each course shall be thoroughly cleaned of all dirt before another
course is laid on top.
2.5.10.4 During inclement weather conditions, newly built brick masonry

works shall be protected by tarpaulin or other suitable covering to
prevent mortar being washed away by rain.
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2.5.10.5 Brickwork shall be kept constantly moist on all the faces for at
least seven days. The arrangement for curing shall be got approved
from the ENGINEER.
2.5.10.6 Double scaffolding having two sets of vertical supports shall be

provided to facilitate execution of the masonry works. The scaffolding
shall be designed adequately considering all the dead, live and possible
impact loads to ensure safety of the workmen, in accordance with the
requirements stipulated in IS:2750 and IS:3696 (Part 1). Scaffolding
shall be properly maintained during the entire period of construction.
Single scaffolding shall not be used on important works and will be
permitted only in certain cases as decided by the ENGINEER. Where
single scaffolding is adopted, only minimum number of holes, by
omitting a header shall be left in the masonry for supporting horizontal
scaffolding poles. All holes in the masonry shall be carefully made
good before plastering/painting.
2.5.10.7 In the event of usage of traditional bricks of size 230

mmx115mmx75mm for load bearing walls, the courses at the top of the
plinth and sills as well as at the top of the wall just below the roof/floor
or slabs and at the top of the parapet shall be laid with bricks on edge.
2.5.10.8 All brickwork shall be built tightly against columns, floor slabs or
other structural members.
2.5.10.9 To overcome the possibility of development of cracks in the brick

masonry following measures shall be adopted.
a) For resting RCC slabs, the bearing surface of masonry wall shall
be finished on top with 12 mm thick cement mortar 1:3 and
provided with 2 layers of Kraft paper Grade 1 as per IS:1397 or 2
layers of 50 micron thick polyethylene sheets.
b) RCC/steel beams resting on masonry wall shall be provided with
plain or reinforced concrete bed blocks of dimensions as indicated
in the drawings duly finished on top with 2 layers of Kraft paper ISSUE
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Grade 1 as per IS:1397 or 2 layers of 50 micron thick polyethylene

sheets.
c) Steel wire fabric shall be provided at the junction of brick masonry
and concrete as specified elsewhere before taking up plastering
work.
2.5.10.10 The above items shall be measured and paid for separately under
the respective items of work.
2.5.10.11 Bricks for partition walls shall be stacked adjacent to the structural
member to pre-deflect the structural member before the wall is taken up
for execution. Further, the top most course of half or full brick walls
abutting against either a de-shuttered slab or beam shall be built only
after any proposed masonry wall above the structural member is
executed to cater for the deflection of the structural element.
2.5.10.12 Reinforced cement concrete transoms and mullions of dimensions

as indicated in the construction drawings are generally required to be
provided in half brick partition walls. Reinforced concrete for transoms
and mullions shall be measured and paid for separately under the
2.5.10.13 Where drawings indicate that structural steel sections are to be

encased in brickwork, the brick masonry shall be built closely against
the steel section, ensuring a minimum of 20mm thick cement-sand 1:4
over all the steel surfaces. Steel sections partly embedded in brickwork
shall be provided with bituminous protective coating to the surfaces at
the point of entry into the brick masonry.
2.5.10.14 CONTRACTOR shall note that the unit rates quoted for the
masonry work shall be deemed to include for the installation of
miscellaneous inserts such as pipe sleeves, bolts, steel sections with
anchors etc. and providing pockets, leaving openings, cutting chases
etc. in accordance with the construction drawings. Miscellaneous
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by the CONTRACTOR. Any of the miscellaneous inserts which are

required to be fabricated and supplied by the CONTRACTOR and
cement concrete to be provided for fixing embedments, hold fasts of
door/window frames etc. shall however, be measured and paid
separately under the respective items of work. .
2.5.10.15 Facing bricks of the type specified conforming to IS:2691 shall be

laid in the positions indicated on the drawings and all facing brickwork
shall be well bonded to the backing bricks/RCC surfaces. The level of
execution of the facing brickwork shall at any time be lower by at least
600 mm below the level of the backing brickwork.
2.5.10.16 Facing bricks shall be laid over 10 mm thick backing of cement

mortar. The mortar mix, thickness of joint and the type of painting to be
carried out shall be as specified in the item of work. The pattern of
laying the bricks shall be as specifically indicated in the drawings.
2.5.10.17 For facing brickwork, double scaffolding shall be used.
2.5.10.18 Faced works shall be kept clean and free from damage,
discoloration etc., at all times.
2.5.10.19 Cutting of chases in 230 thick wall and above for routing GI pipes,
CI pipes or for any other services shall preferably be in the vertical
direction. Horizontal chases shall be avoided, as far as possible. The
depth of vertical chases and horizontal chases, if any, shall not exceed
one third and one sixth of the thickness of masonry respectively.
Vertical chases shall not be closer than 2m in any stretch. Not more
than 2 horizontal chases shall be permitted in a stretch of wall and
these should be located in upper or lower one-third of height of wall.
2.5.10.20 No lintel need be provided for circular openings upto 400mm

diameter in 230mm thick wall and above. Similarly, no lintel need be
provided for rectangular holes of 300mm wide and below.
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2.5.11 MEASUREMENT
2.5.11.1 Measurement shall be in cu.m correct to two places of decimal for

brickwork of thickness one brick i.e. 200mm/230mm and above.
Measurement shall be in sq.m correct to two places decimal for facing
brickwork and brickwork of thickness half brick i.e. l00mm/115mm and
below. Measurement shall be for the quantities as actually executed
duly deducting for openings, lintels, transoms/mullions etc. subject to
clauses 2.5.11.2 ,2.5.11.3/2.5.11.4 below.
2.5.11.2 No deductions shall be made for openings less than 0.1sq.m area
or for embedment upto 0.1 sq.m in section.
2.5.11.3 Brick works curved in plan to a mean radius upto 6m shall be

measured and paid as curved wall as a separate item of works. Brick
works curved in plan to a mean radius more than 6m shall be measured
and paid like a straight wall.
2.5.11.4 All concrete works shall he measured and paid for separately
under the respective items of work.
2.6 CONCRETE BLOCK MASONRY
2.6.1 MATERIALS
2.6.1.1 Masonry units of hollow and solid concrete blocks shall conform to the
requirements of IS : 2185 (Part 1).
2.6.1.2 Masonry units of hollow and solid light-weight concrete blocks shall
conform to the requirements of IS: 2185 (Part 2).
2.6.1.3 Masonry units of autoclaved cellular concrete blocks shall conform to

the requirements of IS: 2185 (Part 3).
The nominal dimensions of concrete block shall be as under.
Length 400,500 or 600 mm. ISSUE

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Height 100 or 200 mm.
2.6.1.4 Width 100 to 300 mm in 50 mm increments
2.6.1.5 Half blocks shall be in lengths of 200, 250 or 300 mm to correspond to

the full length blocks. Actual dimensions shall be 10 mm short of the
nominal dimensions.
2.6.1.6 The maximum variation in the length of the units shall not be more than
+ 5mm and maximum variation in height or width of the units shall not
be more than + 3mm.
2.6.1.7 Concrete blocks shall be either hollow blocks with open or closed
cavities or solid blocks.
2.6.1.8 Concrete blocks shall be sound, free of cracks, chipping or other

defects which impair the strength or performance of the construction.
Surface texture shall be as specified. The faces of the units shall be flat
and rectangular, opposite faces shall be parallel and all arises shal1 be
square. The bedding surfaces shall be at right angles to the faces of
the block.
2.6.1.9 The concrete mix for the hollow and solid concrete blocks/light weight
concrete blocks shall not be richer than one part of cement to six parts
of combined aggregates by volume i.e. (1:6).
2.6.1.10 Concrete blocks shall be of approved manufacture, which satisfy

the limitations in the values of water absorption, drying shrinkage and
moisture movement, as specified for the type of block as per relevant IS
code. CONTRACTOR shall furnish the test certificates and also supply
the samples, for the approval of ENGINEER.
2.6.2 WORKMANSHIP
2.6.2.1 The type of the concrete block, thickness and grade based on the
compressive strength for use in load bearing and/or non-load bearing ISSUE
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minimum nominal thickness of non-load bearing internal walls shall be

100 mm. The minimum nominal thickness of external panel walls in
framed construction shall be 200 mm.
2.6.2.2 The workmanship, shall generally conform to the requirements of IS:

2572 for concrete block masonry, IS:6042 for light weight concrete
block masonry and IS:6041 for autoclaved cellular concrete block
masonry works.
2.6.2.3 From considerations of durability, generally concrete block masonry

shall be used only in superstructure works above the damp-proof
course level.
2.6.2.4 Concrete blocks shall be embedded with a mortar which is relatively

weaker than the mix of the blocks in order to avoid the formation of
cracks. Cement mortar of proportion 1:6 shall be used for the works
unless otherwise specified in the respective items of work. Preparation
of mortar shall be as specified in clause 2.5.7 to 2.5.8.
2.6.2.5 The thickness of both horizontal and vertical joints shall be 10 mm. The
first course shall he laid with greater care, ensuring that it is properly
aligned, levelled and plumb since this will facilitate in laying succeeding
courses to obtain a straight and truly vertical wall. For the horizontal
(bedding) joint, mortar shall be spread over the entire top surface of the
block including front and rear as well as the edges to a uniform layer of
10 mm. For vertical joints, the mortar shall be applied on the vertical
edges of the front and rear sides of the blocks. The mortar may be
applied either to the unit already placed on the wall or on the edges of
the succeeding unit when it is standing vertically and then placing it
horizontally, well pressed against the previously laid unit to produce a
compacted vertical joint. To assure satisfactory bond, mortar shall not
be spread too far ahead of actual laying of the block as the mortar will
stiffen and lose its plasticity. Mortar while hardening shrinks slightly
and thus pulls away from the edges of the block. The mortar shall be ISSUE
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pressed against the units with a jointing tool after it has stiffened to
effect intimate contact between the mortar and the unit to obtain a
weather tight joint. The mortar shall be raked to a depth of 10 mm as
each course is laid to ensure good bond for the plaster.
2.6.2.6 Only well dried blocks should be used for the construction. Blocks with
moisture content more than 25% of maximum water absorption
permissible shall not he used. The blocks should not be wetted before
or during laying in the walls. Blocks should be laid dry except slightly
moistening their surface on which mortar is to be applied to obviate
absorption of water from the mortar.
2.6.2.7 For jambs of doors, windows and openings, solid concrete blocks shall
he provided. If hollow units are used, the hollows shall be filled with
concrete of mix 1:3:6. Hold fasts of doors/windows should be arranged
so that they occur at block course level.
2.6.2.8 At intersection of walls, the courses shall be laid up at the same time
with a true masonry bond between at least 50% of the concrete blocks.
The sequence for construction of partition walls and treatment at the top
of load bearing walls for the RCC slab shall be as detailed under clause
3 for the brick work.
2.6.2.9 Curing of the mortar joints shall be carried out for atleast 7 days. The
walls should only be lightly moistened and shall not be allowed to
become excessively wet.
2.6.2.10 Double scaffolding as per clause 3.3.9.6 shall be adopted for

execution of block masonry work.
2.6.2.11 Cutting of the units shall be restricted to a minimum. All horizontal

and vertical dimensions shall be in multiples of half-length and full
height of units respectively, adapting modular co-ordination for walls,
opening locations for doors, windows etc.
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2.6.2.12 Concrete blocks shall be stored at site suitably to avoid any

contact with moisture from the ground and covered to protect against
wetting.
2.6.3 MEASUREMENT
2.6.3.1 Measurement shall be in cum. correct up to two places of decimal for

walls of thickness 200 mm and above. Measurement shall be in sqm
correct up to two places of decimal for walls of 100mm/150mm in
thickness. Measurement shall be for the quantities as actually
executed duly deducting for openings, and concrete works. Concrete
and reinforcement will be measured and paid separately. The rate
quoted shall be for the type of masonry blocks specified in the
respective items of work which shall include for the specific sequential
operations as stipulated in the construction drawings.
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3 FLOORING SKIRTING & DADO WORKS
3.1 GENERAL
3.1.1 The works covered under this specification shall include:
3.1.2 Flooring, Dado and Skirting
3.1.3 Tread and risers for steps
3.2.1 Work shall be carried out as per latest edition of Indian Standards and Code
of Practices. List given here shall not be considered as conclusive and is for
reference and guidance only. Any discrepancies/ conflict noticed shall be
brought to the notice of Architect/Engineer in charge for direction / approval.
However, as a general rule more stringent specification shall take
precedence.
IS: 383 Coarse and fine aggregates from natural sources for
concrete
IS:456 Plain And Reinforced Concrete - Code Of Practice
IS:702 Specification for industrial bitumen.
IS: 777 Specifications for glazed earthenware tiles

IS: 1121 Method for determination of compressive, transverse
and shear strengths of natural building stones
IS: 1122 Methods for determination of specific gravity and
porosity of natural building stones
IS: 1124 Method of test for determination of water absorption
of natural building stones
IS: 1126 Method of test for durability of natural building stones
IS: 1129 Dressing of natural building stones
IS: 1130 Marble (blocks, slabs and tiles)
IS: 1200 Method of measurements of paving, floor finishes, dado
PART II and skirting
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IS: 1443 Code of practice for laying and finishing of cement

concrete flooring tiles
IS: 1580 Bituminous compound for waterproofing and caulking
purposes
IS:1834 - Specification for hot applied sealing compound for joint in
concrete.
IS:1838 - Specification for preformed fillers for expansion joint in

concrete pavements and structures (non extruding and
resilient type) : Part 1 Bitumen impregnated fibre.
IS: 2046 Synthetic Resin Bonded Sheets.

IS: 2114 Code of practice for laying in situ terrazzo floor finish
IS: 2116 Sand for masonry mortars
IS: 2571 Code of practice for laying in situ cement concrete
flooring
IS: 3384 Bitumen primer for use in waterproofing and damp
proofing
IS: 3462 Specification for unbacked flexible PVC flooring.
Is: 4443 Code of practice for use of resin type chemical
resistant mortars
IS: 4457 Specification for ceramic unglazed vitreous acid
resisting tiles.
IS: 4631 Code of practice for laying of epoxy resin floor
topping
IS: 4832 Specification for chemical resistant mortars (Part II)
IS: 5318 Code of practice for laying of flexible PVC sheet &
tile flooring.
IS: 5491 Code of practice for laying in situ granolithic concrete
floor topping
IS: 9162 Methods of test for epoxy resin, hardeners and epoxy
resin composites for floor topping.
IS: 9197 Specification for epoxy resin, hardeners and epoxy
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Is: 12830 Rubber based adhesives for fixing PVC tiles to

cement
IS: 269 Specification of 33 grade ordinary Portland Cement.
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3.3 RUBBLE SUB-BASE
3.3.1 MATERIALS
3.3.1.1 Stone used under grade slab for rubble soling on grade, foundations
etc., shall be clean, hard, durable rock free from veins, flaws,
weathering and other defects. Stones shall generally conform to the
requirements stipulated in IS:1597 (Part-I).
3.3.1.2 Stones shall be as regular as can be obtained from quarries. Stones

shall be of height equal to the thickness of the packing proposed with a
tolerance of + 10mm. Stones shall not have a base area less than 250
sq.cm nor more than 500 sq.cm, and the smallest dimension of any
stone shall not be less than half the largest dimension. The quality and
size of stones shall be subject to the approval of the ENGINEER.
3.3.2 WORKMANSHIP
3.3.2.1 Stones shall be hand packed carefully and laid with their largest base
downwards resting flat on the prepared sub-grade and with their height
equal to the thickness of the packing. Stones shall be laid breaking
joints and in close contact with each other-. All interstices between the
stones shall be wedged-in by small stones of suitable size, well driven
in by crow bars and hammers to ensure tight packing and complete
filling-in of the interstices. The wedging shall be carried out
simultaneously with the placing in position of rubble packing and shall
not lag behind. After this, any interstices between the smaller wedged
stones shall be in-filled with clean hard sand by booming so as to fill the
joints completely.
3.3.2.2 The laid rubble packing shall be sprinkled with water and compacted by
using suitable rammers/rollers.
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3.3.3 MEASUREMENT
3.3.3.1 Measurement shall be in sq.m correct to two places of decimal for the
specified compacted thickness of rubble sub-base.
3.4 BASE CONCRETE
3.4.1 WORKMANSHIP
3.4.1.1 The thickness and grade of concrete shall be as specified in the item of
work.
3.4.1.2 Before placing the blinding concrete, 50/75mm thick as per the item of
work, the sub-base of rubble packing shall be properly wetted and
rammed. Concrete for the base shall then be deposited between the
forms, thoroughly tamped and the surface finished level with the top
edges of the forms. Two or three hours after the concrete has been laid
in position, the surface shall be roughened using steel wire brush to
remove any scum or laitance and swept clean so that the coarse
aggregates are exposed. The surface of the base concrete shall be left
rough to provide adequate bond for the floor finish to be provided later.
3.4.2 MEASUREMENT
3.4.2.1 Measurement shall be in sq.m correct to two places of decimal. This

work could be either separate or combined along with the floor finish as
indicated in the respective items of work.
3.5 TERRAZZO AND PLAIN CEMENT TILING WORKS
3.5.1 Terrazzo tiles and cement tiles shall generally conform in all respects to
standards stipulated in IS:1237. Tiles shall be of the best quality
manufactured adopting hydraulic pressure of not less than 14N/mm 2.
3.5.2 The type, quality, size, thickness colour etc, of the tiles for flooring/dado/
skirting shall be as specified in the respective items of work.
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3.5.3 The aggregates for terrazzo topping shall consist of marble chips which are
hard, sound and dense. Cement to be used shall be either ordinary
Portland cement or white cement with or without colouring pigment. The
binder mix shall be with 3 parts of cement to 1 part of marble powder by
weight. The proportion of cement shall be inclusive of any pigments. For
every one part of cement-marble powder binder mix, the proportion of
aggregates shall be 1.75 parts by volume, if the chips are between l mm to
6mm and 1.50 parts by volume if the chips are between 6mm to 25mm.
3.5.4 The minimum thickness of wearing layer of plain cement and plain coloured
tiles for general purpose and terrazzo tiles with chips upto 6mm to 12mm
general purpose is 5mm thick tiles. Terrazo tiles with chips of size up to
20mm for heavy duty and general purpose and plain cement and plain
coloured tiles for heavy duty shall be 6mm thick tiles. Pigment used in the
wearing layer shall not exceed 10 percent of the weight of cement used in
the mix.
3.5.5 WORKMANSHIP
3.5.5.1 Laying and finishing of tiles shall conform to the requirements of

workmanship stipulated in IS:1443.
3.5.5.2 Tiling work shall be commenced only after the door and window frames
are fixed and plastering of the walls/ ceiling is completed. Wall
plastering shall not be carried out up to about 50mm above the level of
proposed skirting/dado.
3.5.5.3 The base concrete shall be finished to a reasonably plane surface

about 40 to 45mm below the level of finished floor. Before the tiling
work is taken up, the base concrete or structural slab shall be cleaned
of all loose materials, mortar droppings, dirt, laitance etc. using steel
wire brush and well wetted without allowing any water pools on the
surface.
3.5.5.4 A layer of 25mm average thickness of cement mortar consisting of one ISSUE
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tiles over the base concrete. The thickness of bedding mortar shall not
be less than l0mm at any place. The quantity of water to be added for
the mortar shall be just adequate to obtain the workability for laying.
Sand for the mortar shall conform to IS:2116 and shall have minimum
fineness modulus of 1.5. The surface shall be left rough to provide a
good bond for the tiles. The bedding shall be allowed to harden for a
day before laying of the tiles.
3.5.5.5 Neat cement slurry using 4.4 kg of cement per one sq.m of floor area
shall be spread over the hardened mortar bedding over such an area at
a time as would accommodate about 20 tiles. Tiles shall be fixed in this
slurry one after the other, each tile being gently tapped with a wooden
mallet till it is properly bedded and in level with the adjoining tiles. The
joints shall be in straight lines and shall normally be 1.5mm wide. On
completion of laying of the tiles in a room, all the Joints shall be cleaned
and washed fairly deep with a stiff broom/wire brush to a minimum
depth of 5mm. The day after the tiles have been laid, the joints shall be
filled with cement grout of the same shade on the colour of the matrix of
the tile. For this purpose white cement or grey cement with or without
pigments shall be used. The flooring should be kept moist and left
undisturbed for 7 days for the bedding/joints to set properly. Heavy
traffic shall not be allowed on the floor for at least 14 days after fixing of
the tiles.
3.5.5.6 About a week after laying the tiles, each and every tile shall be lightly
tapped with a small wooden mallet to find out if it gives a hollow sound;
if it does, such tiles along with any other cracked or broken tiles shall be
removed and replaced with new tiles to proper line and level. The same
procedure shall be followed again after grinding the tiles and all
damaged tiles replaced, properly jointed and finished to match. For the
purpose of ensuring that such replaced tiles match with those laid
earlier, it is necessary that the CONTRACTOR shall procure sufficient
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3.5.5.7 Wherever a full tile cannot be provided, tiles shall be cut to size and
fixed. Floor tiles adjoining the wall shall go about 10mm under the
plaster, skirting or dado.
3.5.5.8 Tile skirting and dado work shall be executed only after laying tiles on
the floor. For dado and skirting work, the vertical wall surface shall be
thoroughly cleaned and wetted. Thereafter it shall be evenly and
uniformly covered with 12mm thick backing of 1:4 cement sand mortar.
For this work the tiles as obtained from the factory shall be of the size
required and practically full polished. The back of each tile to be fixed
shall be covered with a thin layer of neat cement paste and the tile shall
then be gently tapped against the wall with a wooden mallet. Fixing
shall be done from the bottom of the wall upwards. The joints shall be in
straight lines and shall normally be 1.5mm wide. Any difference in the
thickness of the tiles shall be evened out in the backing mortar or
cement paste so that the tile faces are in conformity & truly plumb. Tiles
for use at the corners shall be suitably cut with bevelled edges to obtain
a neat and true joint. After the work has set, hand polishing with
carborundum stones shall be done so that the surface matches with the
floor finish.
3.5.5.9 Wall plastering of the strip left out above the level of skirting/dado shall
be taken up after the tiles are fixed.
3.5.5.10 CONTRACTOR shall note that the unit rate quoted for skirting
shall also include for any chipping of the brick work required to be
carried out for this item.
3.5.5.11 Chequered terrazzo tiles for flooring and for stair treads shall be
delivered to site after the first machine grinding.
3.5.5.12 Machine grinding and polishing shall be commenced only after a

gap of 14 days of laying. The sequence and three numbers of machine
grinding operations, usage of the type of carborundum stones, filling up
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of pin holes, watering etc. shall be carried out all as specified in

IS:1443.
3.5.5.13 Tiles shall be laid to the levels specified. To ensure this, finished
floor levels should be marked at all door locations and also on the floor
at frequent intervals. Where large areas are to be tiled the level of the
central portion shall be kept l0mm higher than that at the walls to
overcome optical illusion of a depression in the central portion.
Localized deviation of  3mm in any 3m length is acceptable in a
nominally flat floor.
3.5.5.14 All corners shall be in perfect right angle matching up with the
corners of walls. If due to any misalignment during construction, the
corners of wall are not at right angle, adjustment shall be made in the
title portion lying below skirting.
3.5.5.15 Flooring in toilets, kitchen shall be taken up only after fixing water
closet, squatting pans & floor traps.
3.6 IN-SITU TERRAZZO WORK
3.6.1 The aggregates for terrazzo topping shall consist of marble chips which are
hard, sound and dense.
3.6.2 Cement to be used shall be either ordinary Portland cement or white

cement with or without colouring pigment.
3.6.3 The binder mix shall be with 3 parts of cement to 1 part of marble powder
by weight. The proportion of cement shall be inclusive of any pigments. For
every one part of cement-marble powder binder mix, the proportion of
aggregates shall be 1.75 parts by volume, if the chips are between l mm to
6mm and 1.50 parts by volume if the chips are between 6mm to 25mm.
3.6.4 WORKMANSHIP
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3.6.4.1 Cement shall first be mixed with the marble powder in dry state. The
mix thus obtained shall be mixed with the aggregates in the specified
proportions.
3.6.4.2 Care shall be taken not to get the materials into a heap which results in
the coarsest chips falling to the edges and cement working to the centre
at the bottom.
3.6.4.3 Materials shall be kept, as far as possible, in an even layer during

mixing. After the materials have been thoroughly mixed in the dry state,
water shall be added, just adequate to obtain plastic consistency for the
desired workability for laying.
3.6.4.4 The mix shall be used in the works within 30 minutes of the addition of
water to the cement.
3.6.4.5 The thickness, type, quality, size and colour of chips etc. for the in-situ
terrazzo finish for flooring/dado skirting shall be as specified in the
respective items of work. Laying and finishing of in-situ work shall
conform to the requirements of workmanship stipulated in IS: 2114.
3.6.4.6 In-situ terrazzo finish shall be laid over hardened concrete base. The
finish layer consists of an under layer and terrazzo topping. The under
layer shall be of cement concrete of mix 1:2:4 using l0mm downgraded
coarse aggregates. The combined thickness of under layer and topping
shall not be less than 30 mm for flooring and 20mm for dado/skirting
work.
3.6.4.7 The minimum thickness of topping shall be 6mm if chips used are
between 1mm to 4mm, 9mm if chips are between 4mm to 7mm and
12mm if chips are between 7mm to l0mm. If chips larger than l0mm
size are used, the minimum thickness shall be one and one third the
maximum size of chips.
3.6.4.8 Both the under layer and later the topping shall be divided into panels ISSUE
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development of cracks. The longer dimension of any panel shall not

exceed 2m. Dividing strips shall be used to separate the panels. When
the dividing strips are not provided, the bays shall be laid alternately,
allowing an interval of at least 24 hours between laying adjacent bays.
3.6.4.9 Dividing strips shall be either of aluminum, brass, glass or other

material as indicated in the item of work. Aluminum strips should have a
protective coating of bitumen. The thickness of the strips shall be not
less than 1.5mm and width not less than 25mm for flooring work.
3.6.4.10 Concrete base shall be finished to a reasonably plane surface to a

level below the finished floor elevation equal to the specified thickness
of terrazzo finish. Before spreading the under-layer, the base concrete
surface shall be cleaned of all loose materials, mortar droppings, dirt,
laitance etc. and well wetted without allowing any water pools on the
surface. Dividing strips or screed strips, if dividing strips are not
provided, shall be fixed on the base and leveled to the correct height to
suit the thickness of the finish. Just before spreading the under-layer
the surface shall be smeared with cement slurry at 2.75 Kg/sq.m. Over
this slurry, the under-layer shall be spread and leveled with a screed
board. The top surface shall be left rough to provide a good bond for
the terrazzo topping.
3.6.4.11 Terrazzo topping shall be laid while the under-layer is still plastic
and normally between 18 to 24 hours after the under-layer is laid.
Cement slurry of the same colour as the topping shall be brushed on
the surface immediately before laying is commenced. The terrazzo mix
shall be laid to a uniform thickness and compacted thoroughly by
tamping and with a minimum of trowelling. Straight edge and steel
floats shall be used to bring the surface true to the required level in
such a manner that the maximum amount of marble chips come up and
spread uniformly all over the surface.
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3.6.4.12 The surface shall be left dry for air-curing for a period of 12 to 18
hours. Thereafter it shall be cured by allowing water to stand in pools
for a period of not less than 4 days.
3.6.4.13 Machine grinding and polishing shall be commenced only after a

gap of 7 days from the time of completion of laying. The sequence and
four numbers of machine grinding operations, usage of the type of
carborundum stones, filling up of pinholes, wet curing, watering etc
shall be carried out all as specified in IS: 2114. Where machine
polishing is not possible, polishing shall be carried out by hand in the
same sequence and procedure as for machine polishing.
3.6.4.14 Where the dampness from ground may find its way to the top of
floor, concrete floor on the ground or basement shall be provided with
an effective damp proof.
3.6.4.15 Flooring in toilet and kitchen shall be taken up after fixing water
closet, squatting pans and floor trap.
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3.7 IN-SITU CEMENT CONCRETE FLOOR TOPPING
3.7.1 The mix proportion for the in-situ concrete floor topping shall be
1:2.5:3.5(one part cement: two and half parts sand : three and half parts
coarse aggregates) by volume unless otherwise specified in the item of
work.
3.7.2 The aggregates shall conform for the requirements of IS:383.
3.7.3 Coarse aggregates shall have high hardness surface texture and shall
consist of crushed rock of granite, basalt, trap or quartzite. The aggregate
crushing value shall not exceed 30 percent. The grading of the coarse
aggregates shall be of size 12.5mm and below and shall be as per IS:2571.
3.7.4 Grading of the sand shall be within the limits indicated in IS:2571.
3.7.5 WORKMANSHIP
3.7.5.1 The thickness of the floor topping shall be as specified in the item of
work. The minimum thickness of the floor topping shall be 25mm, if it is
laid separately. 15mm thick wearing course of cement concrete 1:2 (1
cement:2 stone) aggregate of size 4.75mm & below) by volume shall be
applied monolithically over floor topping, if called for in the schedule of
item. Wearing course shall be 20mm thick, if it is cast monolithically
over ground floor slab. Laying and finishing of in-situ topping shall
conform to the requirements of IS 2571.
3.7.5.2 The surface shall be rough to provide adequate bond for the topping. It
shall be finished to a level below the finished floor equal to the
thickness of topping and / or wearing courses, if specified.
3.7.5.3 Mixing of concrete shall be done thoroughly in a mechanical mixer

unless hand mixing is specifically permitted by the ENGINEER. The
concrete shall be as stiff as possible and the amount of water added
shall be the minimum necessary to give just sufficient plasticity for
laying and compacting. The mix shall be used in the work within 30
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3.7.5.4 Floor finish shall be laid in suitable panels to reduce the risk of cracking.
No dimension of a panel shall exceed 2 meters and the length of a
panel shall not exceed one and a half times its breadth. Topping shall
be laid in alternate panels, the intermediate panels being cast after a
gap of at least one day. Construction joints shall be plain vertical butt
joints.
3.7.5.5 Screed strips shall be fixed dividing the area into suitable panels.
Immediately before depositing the concrete topping, neat cement slurry
at 2.75 kg/sq.m of area shall be thoroughly brushed into the prepared
surface. Topping shall then be laid, very thoroughly tamped, struck off
level and floated with wooden float. The surface shall then be tested
with a straight edge and mason's spirit level to detect any inequalities
from that specified in the drawings and these shall be made good
immediately.
3.7.5.6 Finishing of the surface by trowelling shall be spread over a period of

one to six hours depending upon the temperature and atmospheric
conditions. The surface shall be trowelled 3 times at intervals so as to
produce a smooth uniform and hard surface. Immediately after laying,
the first trowelling just sufficient to give a level surface shall be carried
out avoiding excessive trowelling at this stage. The surface shall be re-
trowelled after sometime to close any pores and to scrap off excess
water or laitance, which shall not be trowelled back into the topping.
Final trowelling shall be done well before the concrete has become too
hard but at a time when considerable pressure is required to make any
impression on the surface. Sprinkling of dry cement or cement-sand
mixture for absorbing moisture shall not be permitted.
3.7.5.7 Immediately after the surface is finished, it shall be protected suitably

from rapid drying due to wind/ sunlight. After the surface has hardened
sufficiently to prevent any damage to it, the topping shall be kept
continuously moist for a minimum period of 10 days.
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3.7.5.8 It is preferable to lay the topping on hardened base concrete, as against

being laid monolithically with a lesser thickness, since proper levels and
slopes with close surface tolerance, is achievable in practice, owing to
its greater thickness. Further, as this would be laid after all other
building operations are over, there will be no risk of any damages or
discoloration to the floor finishes which are difficult to repair
satisfactorily.
3.7.5.9 In severe condition, where dampness from ground may find its way on
the top of the floor, the floor slab shall be cast in two equal halves. The
top surface of bottom half shall be made plane and smooth after it is
cast. A coat of bitumen primer conforming to IS 3384 shall be applied
on the hard surface over which two coats of bitumen conforming to IS
1580 shall be applied @ 1.5 kg/m2 for each layer. After the bitumen
surface is dry, the top half of floor slab shall be cast.
3.8 IN-SITU GRANOLITHIC CONCRETE FLOOR TOPPING
3.8.1 The requirements of materials and workmanship shall be same as in situ

terrazzo work floor topping except that the mix proportion of the concrete
shall be 1:1:2 (cement:sand:coarse-aggregates) by volume.
3.8.2 The thickness of the floor topping shall be as specified in the item of work.
The minimum thickness of granolithic floor topping on hardened concrete
base shall be 40mm, if laid separately. It shall be 20mm, if the topping is
laid monolithically over the floor concrete.
3.9 FLOOR HARDENER TOPPING
3.9.1 Floor hardener topping shall be provided either as integrally finished over
the structural slab/grade slab or laid monolithically with the
concrete/granolithic floor finish on top of hardened concrete base.
3.9.2 Floor hardener of the metallic or non-metallic type suitable for the
performance of normal/medium/heavy duty function of the floor, the
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quantum of ingredients and the thickness of topping shall be as specified in

the respective items of work.
3.9.3 For monolithic application with the floor finish/slab, the thickness of the
layer shall be 15mm. It shall be 20mm if it is laid separately over floor slab.
The topping shall be laid within 2 to 3 hours after concrete is laid and it is
still plastic but stiffened enough for the workmen to tread over it by placing
planks. The surface of the concrete layer shall be kept rough for providing
adequate band for the topping. Laitance shall be removed before placing
the topping. The topping shall be screeded and thoroughly compacted to
the finished level. After the surface has hardened sufficiently, it shall be
kept continuously moist for at least 10 days.
3.9.4 The procedure for mixing the floor hardener topping shall be as per
manufacturer's instructions.
3.9.5 Floor hardener topping shall be prevented from any damages due to
subsequent building operations by covering with 75 mm thick layer of sand,
if it is laid monolithically with the slab.
3.10 EPOXY LINING WORK
3.10.1 The epoxy resin and hardener formulation for laying of Pointless lining work
in floors and walls of concrete tanks/trenches, floor toppings etc shall be as
per the requirements of IS:9197. Method of laying shall be as per the
requirements of IS 4631.
3.10.2 The epoxy composition shall have the chemical resistance to withstand the
conditions of exposure like Hydrochloric acid up to 30% concentration,
Sodium hydroxide up to 50% concentration, Liquid temperature up to 60"C,
Ultraviolet radiation, Alternate wetting and drying.
3.10.3 Epoxy resin shall be of liquid type of suitable grade and class as
recommended by the manufacturer.
3.10.4 The hardener shall be of the liquid type such as Aliphatic Amine or an
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suitable characteristics. The hardener shall react with epoxy resin at normal
ambient temperature above 5oC.
3.10.5 Sand shall conform to grading zone III or IV of IS 383.
3.10.6 Accelerator, plasticizer and coal tar may be added for the preparation of
epoxy composition, to the proportion as recommended in IS 9197.
3.10.7 CONTRACTOR shall furnish test certificates for satisfying the requirements
of the epoxy formulation if so directed by the ENGINEER.
3.10.8 WORKMANSHIP
3.10.8.1 The minimum thickness of epoxy lining shall be as recommended

in IS 4631 based on type of application & usage. The thickness and
areas of application shall be as specified in the respective items of
work. It is essential that the base concrete is properly cured, dried and
made rough at the time of application.
3.10.8.2 The epoxy lining shall be of the trowel type to facilitate execution
of the required thickness for satisfactory performance.
3.10.8.3 The concrete surfaces over which epoxy lining is to be provided

shall be thoroughly cleaned of oil or grease by suitable solvents, wire
brushed to remove any dirt/dust and laitance. The surfaces shall then
be washed with dilute hydrochloric acid (10% to 15%) and rinsed
thoroughly with plenty of water or dilute ammonia solution. The surfaces
shall then be allowed to dry. It is essential to ensure that the surfaces
are perfectly dry and even, before the commencement of epoxy
application.
3.10.8.4 Just adequate quantity of epoxy resin which can be applied within
the pot life as specified by the manufacturer shall be prepared at one
time for laying and jointing.
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3.10.8.5 Rigid PVC/stainless steel/chromium plated tools shall be used for

laying. Trowelling shall be carried out to obtain uniformly the specified
thickness of lining.
3.10.8.6 Lining shall be allowed to set without disturbance for a minimum

period of 24 hours. The facility shall be put to use only after a minimum
period of 7 days of laying of the lining.
3.10.8.7 For epoxy lining over the inside concrete surfaces of underground
tank or trenches, it should be ensured that they are leak proof against
water by conducting leakage test.
3.11 SHAHABAD / TANDUR / KOTA STONE / GRANITE / MARBLE SLAB

WORK
3.11.1 The slabs shall be of approved selected quality, hard, sound, dense and
homogenous in texture, free from cracks, decay, weathering and flaws. The
percentage of water absorption shall not exceed 5 percent as per test
conducted in accordance with IS:1124.
3.11.2 The slabs shall be hand or machine cut to the required thickness. Tolerance
in thickness for dimensions of tile more than 100 mm shall be ±5mm. This
shall be + 2mm on dimensions less than l00mm.
3.11.3 Slabs shall be supplied to the specified size with machine cut edges or fine
chisel dressed to the full depth. All angles and edges of the slabs shall be
true and square, free from any chipping giving a plane surface. Slabs shall
have the top surface machine polished (first grinding) before being brought
to site. The slabs shall be washed clean before laying.
3.11.4 WORKMANSHIP
3.11.4.1 The type, size, thickness and colour/shade etc. of the slabs for
flooring/dado/ skirting shall be as specified in the respective items of the
work.
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3.11.4.2 Concrete base shall be prepared and finished below the finished
floor level equal to the thickness of stone slab and cement mortar
below.
3.11.4.3 The thickness of the slabs for dado/skirting work shall not be more
than 25mm. Slabs shall be so placed that the back surface is at a
distance of 12mm from the wall. If necessary, slabs shall be held in
position temporarily by suitable method. After checking for verticality,
the gap shall be filled and packed with cement sand mortar of
proportion 1:3. After the mortar has acquired sufficient strength, the
temporary arrangement holding the slab shall be removed. The
recommended mortar mix for joints and beddings for stone blocks shall
be two parts of white cement and seven parts of stone dust. The
thickness of joints shall be 5 mm. For fixing of stones to the walls, fixing
clamps of non-ferrous metal should be used.
3.11.4.4 Grinding and polishing shall be as per clause 3.6.4.13 except that
first grinding with coarse grade carborundum shall not be done and
cement slurry with or without pigment shall not be applied before
polishing.
3.12 CARBORUNDUM TILE FINISH
3.12.1 Carborundum tiles shall generally conform in all respects to the

standards stipulated in IS: 1237 for heavy duty tiles. Tiles shall be of the
best quality manufactured adopting hydraulic pressure of not less than 14
N/mm2.
3.12.2 Each tile shall bear on its back, permanent and legible trade mark of the
manufacturer. All angles of the tiles shall be right angle, all edges sharp and
true, colour and texture of the wearing face uniform throughout. Maximum
tolerance/allowance for length and breadth shall be +1 mm and thickness
+3mm along the wearing surface of the tile and the wearing surface shall be
planed free from pin-holes and other blemishes.
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3.12.3 The backing shall be composed of 1 part ordinary grey cement, 2 parts
sand and 4 parts of stone chips by volume and mixed with water.
3.12.4 The topping shall be uniform and of thickness not less than 6mm. The
quantity of carborundum grit shall be not less than 1.35 kg/sq.m used with
cement with or without pigment. The carborundum grit shall pass through
1.18mm mesh and shall be retained on 0.60mm mesh. The total
thickness of tiles including the topping shall be not less than 20 mm.
3.12.5 The tile shall be cured at the shop for at least 14 days before delivery to
site. Tiles shall be packed properly to prevent damage during transit and
storage. The tiles must be stored carefully to prevent staining by damp,
rust, oil and grease or other chemicals. Tiles made in each batch shall be
kept and used separately so that the colour of each area of floor may
remain uniform.
3.12.6 The manufacturer shall supply along with the tiles the grout mix containing
cement and pigment in exact proportions as used in topping of tiles. The
containers of the grout mix shall be suitably marked to relate it to the
particular type and batch of tiles
3.12.7 The size, thickness, colour and plain or chequered etc. of the tiles for
flooring/skirting shall be as specified in the respective items of work. The
under bed for floors shall be 1 part cement: 2 parts coarse sand: 4 parts
stone aggregate by volume mix with sufficient water to form a stiff workable
mass. For skirting and dado, it shall be 1 part cement: 3 parts coarse sand
by volume.
3.12.8 The total average thickness shall be minimum 50 mm for floors and 30 mm
for walls.
3.12.9 WORKMANSHIP
3.12.9.1 Requirements as detailed for terrazzo/cement tile finish shall be

applicable to carborundum tile flooring.
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3.13 VITRIFIED TILES / CERAMIC TILES / GLAZED TILE FINISH R4

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3.13.1 Tiles shall be of the best quality from an approved manufacturer. The tiles
shall be flat, true to shape and free from flaws such as crazing, blisters,
pinholes, specks or welts. Edges and underside of the tiles shall be free
from glaze and shall have ribs or indentations for a better anchorage with
the bedding mortar. Dimensional tolerances shall be as specified in IS:
13756.
3.13.2 WORKMANSHIP
3.13.2.1 The size, thickness, colour, with or without designs etc of the tiles
for flooring/dado/skirting shall be as specified in the respective items of
work.
3.13.2.2 The total thickness of glazed tile finish including the bedding
mortar shall be maximum 20 mm in flooring/dado/skirting. The minimum
thickness of bedding mortar shall be 12mm for flooring and l0mm for
dado/skirting work.
3.13.2.3 The bedding mortar shall consist of 1 part of cement to 3 parts of

sand mixed with just sufficient water to obtain proper consistency for
laying. Sand for the mortar shall conform to IS: 2116 and shall have
minimum fineness modules of 1.5
3.13.2.4 Tiles shall be soaked in water for about 10 minutes just before
laying. Where full size tiles cannot be fixed, tiles shall be cut to the
required size using special cutting device and the edges rubbed smooth
to ensure straight and true joints.
3.13.2.5 Coloured tiles with or without designs shall be uniform and shall be
preferably procured from the same batch of manufacture to avoid any
differences in the shade.
3.13.2.6 Tiles for the flooring shall be laid over hardened concrete base.
The surface of the concrete base shall be cleaned of all loose materials,
mortar droppings etc well wetted without allowing any water pools on
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surface, tamped to the desired level and allowed to harden for a day.
The top surface shall be left rough to provide a good band for the tiles.
For skirting and dado work, the brick walls shall be raked to a depth of
15mm. In case of concrete walls, the surfaces shall be hacked. The
raked / hacked masonry surfaces shall be cleared, wet and then the
bedding mortar to specified thickness shall be applied. The mortar
surfaces shall be roughened using wire brush and allowed to harden.
3.13.2.7 Neat cement slurry using 3.3 kg cement per one sq.m of floor area
shall be spread over the hardened mortar bed over such an area as
would accommodate about 20 tiles. Tiles shall be fixed in this slurry one
after the other, each tile being gently tapped with a wooden mallet till it
is properly bedded and in level with the adjoining tiles. For skirting and
dado work, the back of the tiles shall be smeared with cement slurry for
setting on the backing mortar.
3.13.2.8 Fixing of tiles shall be done from the bottom of the wall upwards.
The joints shall be in perfect straight lines and as thin as possible but
shall not be more than l mm wide. Tiles used for corners shall be
suitably beveled to obtain a true and neat joint. The surface shall be
checked frequently to ensure correct level/required slope. Floor tiles
near the walls shall enter skirting/dado to a minimum depth of 10mm.
Tiles shall not sound hollow when tapped.
3.13.2.9 All the joints shall be cleaned of grey cement with wire brush to a
depth of at least 3mm and all dust, loose mortar etc. shall be removed.
White cement with or without pigment shall then be used for flush
pointing the joints. Curing shall then be carried out for a minimum
period of 7 days for the bedding and joints to set properly. The surface
shall then be cleaned using a suitable detergent, fully washed and
wiped dry.
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3.13.2.10 Specials consisting of coves, internal and external angles,

cornices, beads and their corner pieces shall be of thickness not less
than the tiles with which they are used.
3.14 PVC / VINYL SHEET/TILE FLOORING
3.14.1 PVC/VINYL floor covering shall be of either unbacked homogeneous

flexible type in the form of sheets/tiles conforming to IS:3462 or
homogeneous PVC asbestos tiles conforming to IS:3461.
3.14.2 The surface of the sheets/tiles shall be free from any physical defects such
as pores, blisters, cracks etc. which affects the appearance and
serviceability. Tiles/sheets shall meet with the tolerance limits in dimensions
specified in the IS codes. CONTRACTOR shall submit the test certificates,
if so desired by the ENGINEER.
3.14.3 Each tile/sheet shall be legibly and indelibly marked with the name of the
manufacturer or his trade mark, IS certificate mark and batch number.
3.14.4 The adhesive to be used for laying the PVC/VINYL flooring shall be rubber
based conforming to IS 12830 and of the make as recommended and
approved by the manufacturer of PVC/VINYL sheets/tiles.
3.14.5 The type, size, thickness, colour, plain or mottled and the pattern shall be
as specified in the respective items of work.
3.14.6 WORKMANSHIP
3.14.6.1 Laying of PVC / VINYL sheets / tiles shall conform IS 5318. PVC /
VINYL floor covering shall be provided over an under bed of cement
concrete floor finish over the base concrete or structural slab. It is
essential that the sub-floor and the under bed are perfectly dry before
laying the PVC / VINYL flooring. This shall be ensured by methods of
testing as stipulated in Appendix-A of IS:5318. Concrete floor on the
ground / basement shall be treated with an effective damp proof course.
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3.14.6.2 The surface of the under bed shall have trowelled finish without
any irregularities which creates poor adhesion. Surface shall be free of
oil or grease and thoroughly cleaned of all dust, dirt and wiped with a
dry cloth.
3.14.6.3 PVC / VINYL sheets/tiles shall be brought to the temperature of

the area in which they are to be laid by stacking in a suitable manner
within or near the laying area for a period of about 24 hours. Where air-
conditioning is installed, the flooring shall not be laid on the under bed
until the A/C units have been in operation for at least 7 days. During this
period, the temperature range shall be between 200C and 300C and
this shall be maintained during the laying operations and also for 48
hours thereafter.
3.14.6.4 Layout of the PVC / VINYL flooring shall be marked with

guidelines on the under bed and PVC / VINYL tiles/sheets shall be first
laid for trial, without using the adhesive, according to the layout.
3.14.6.5 The adhesive shall be applied by using a notched trowel to the

surface of the under bed and to the backside of PVC / VINYL
sheets/tiles. When the adhesive has set sufficiently for laying, it will be
tacky to the touch, which generally takes about 30 minutes. The time
period need be carefully monitored since a longer interval will affect the
adhesive properties. Adhesive shall be uniformly spread over only as
much surface area at one time which can be covered with PVC / VINYL
flooring within the stipulated time.
3.14.6.6 PVC / VINYL sheet shall be carefully taken and placed in position
from one end onwards slowly so that the air will be completely
squeezed out between the sheet and the background surface and no
air pockets are formed. It shall then be pressed with a suitable roller to
develop proper contact. The next sheet shall be laid edge to edge with
the sheet already laid, so that there is minimum gap between joints.
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The alignment shall be checked after each row of sheet is completed

and trimmed if considered necessary.
3.14.6.7 Tiles shall be laid in the same manner as sheets and preferably,
commencing from the centre of the area. Tiles should be lowered in
position and pressed firmly on to the adhesive with minimum gap
between the joints. Tiles shall not be slided on the surface. Tiles shall
be rolled with a light wooden roller of about 5kg to ensure full contact
with the underlay. Work should be constantly checked to ensure that all
four edges of adjacent tiles meet accurately.
3.14.6.8 Any excess adhesive which may squeeze up between sheets/tiles

shall be wiped off immediately with a wet cloth. Suitable solvents shall
be used to remove hardened adhesive.
3.14.6.9 A minimum period of 24 hours shall be given after laying for the
development of proper bond of the adhesive. When the flooring in thus
completed, it shall be cleaned with a wet cloth soaked in warm soap
solution.
3.14.6.10 Metallic edge strips shall be used to protect the edges of PVC /
VINYL sheets/tiles which are exposed as in doorways/ stair treads.
3.14.6.11 Hot sealing of joints between adjacent PVC / VINYL sheet flooring
to prevent creeping of water through the Joints shall be carried out, if
specified in the item of work, using special equipment as per
manufacturer's instructions.
3.14.6.12 It is desirable that the PVC / VINYL flooring are taken up after
completing all other works in the area so as to avoid any accidental
damage to the flooring.
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3.15 ACID RESISTANT TILES
3.15.1 The ceramic unglazed vitreous acid resisting tiles shall conform to the
requirements of IS: 4457.
3.15.2 The finished tile when fractured shall appear fine grained in texture, dense
and homogeneous. Tile shall be sound, true to shape, flat, free from flaws
and any manufacturing defects affecting their utility. Tolerance in the
dimensions shall be within the limits specified in the respective IS code.
3.15.3 The tiles shall be bedded and jointed using chemical resistant mortar
prepared from resin type conforming to IS: 4832 (Part II) filter, accelerator
and catalyst mixed in proportion as recommended by manufacturers.
Method of usage shall generally be as per the requirements of IS: 4443.
3.15.4 WORKMANSHIP
3.15.4.1 The size and thickness of tiles for use in the flooring/skirting/dado
shall be as specified in the respective items of work.
3.15.4.2 The base concrete surface shall be free from dirt and thoroughly
dried. The surface shall be applied with a coat of bitumen primer
conforming to IS: 3384. The primed surface shall then be applied with a
uniform coat of bitumen conforming to IS: 1580. Tiles shall be laid
directly without the application of bitumen, if epoxy or polyester resin is
used for the mortar.
3.15.4.3 Just adequate quantity of mortar which can be applied within the
pot life as specified by the manufacturer shall be prepared at one time
for bedding and jointing. Rigid PVC/Stainless steel/chromium plated
tools shall be used for mixing and laying.
3.15.4.4 For laying the floor 6 to 8 mm thick mortar shall be spread on the
back of the tile. Two adjacent sides of the tile shall be smeared with 4 to
6 mm thick mortar. Tile shall be pressed into the bed and pushed
against the floor and with the adjacent tile, until the joint in each case is ISSUE
2 to 3 mm thick. Excess mortar shall then be trimmed off and allowed to R4
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harden fully. Similar procedure shall be adopted for the work on walls
by pressing the tile/brick against the prepared wall surfaces and only
one course shall be laid at a time until the initial setting period.
3.15.4.5 The mortar joints shall be cured for a minimum period of 72 hours
with 20 to 25% hydrochloric acid or 30 to 40% sulphuric acid. After acid
curing, the joints shall be washed with water and allowed to thoroughly
dry. The joints shall then be filled with mortar to make them smooth and
plane. Acid curing is not required to be carried out if epoxy or polyester
resin is used for the mortar.
3.15.4.6 Resin mortars are normally self curing. The area tiled shall not be
put to use before 48 hours in case epoxy, polyester and furane type of
resin is used for the mortar. If phenol or cashew nut shell liquid resin is
used for the mortar, the area tiled shall not be put to use for 7 to 28
days respectively, without heat treatment. This period shall be 2 to 6
days respectively if heat treatment is given with infrared lamp.
3.15.4.7 Temperature during preparation of mortar, its application, curing

etc. shall be controlled and maintained as recommended by
manufacturer.
3.15.4.8 It is necessary that the concrete slab / wall shall be made leak
proof against water, if necessary by pressure grouting etc. before taking
up any titling works. Cost of such works shall be deemed to have
included in the cost of tiling works, whether same is specifically
mentioned or not.
3.16 STAMPED CONCRETE PAVING WORKS
3.16.1 Concrete Mix Design - The concrete shall have a minimum compressive
strength of 3,000 psi in non-freeze areas, 3,500 psi in moderate freeze-
thaw areas and 4,000 psi in severe freeze-thaw areas. Portland cement &
Aggregates shall conform to IS. Mixing water shall be fresh, clean and
potable. No admixtures containing calcium chloride shall be permitted. ISSUE
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3.16.2 Dry-Shake Coloured Hardener - Cementitious material containing special

hard aggregates, formulated as a high opacity colour hardening material for
the top surface of freshly place concrete substrates. Highly UV-resistant.
Factory proportioned, mixed and packaged, ready-to-use. Comply with IS
9197.
3.16.3 Low VOC Liquid Release Agent - Colourless, odourless liquid formulated to
break the bond between imprinting tools and surface of colour-hardened
concrete. Evaporates completely, leaving no residue. VOC content less
than 450 g/L (3.75lb/gal).
3.16.4 Curing and sealing compound
3.16.5 WORKMANSHIP / FABRICATION AND ERECTION
3.16.5.1 Sub grade Preparation
3.16.5.2 The area to receive imprinted concrete shall have the sub-grade
prepared as required as for any concrete slab on grade.Sub grade to
receive stamped concrete paving work must be well drained and have
adequate, uniform load bearing characteristics.
3.16.5.3 Concrete Placement
3.16.5.4 Place and spread concrete to completely fill all space inside forms.
Move concrete into place with square-tipped shovels or concrete rakes.
Consolidate concrete by tamping or vibrating to provide a suitable
surface for finishing. Prior to appearance of excess moisture or bleed
water, screed concrete with wood or magnesium straight edge or
mechanical vibrating screed. Continue concrete surface leveling and
consolidation with highway magnesium straight edge and (or)
magnesium bull float. Mechanically float concrete surfaces to required
flatness and levelness as soon as concrete surface has taken its initial
set and will support weight of a power float machine equipped with float
shoes or combination blades and operator. Completed concrete
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placement to result in an open surface suitable to receive colored

hardener.
3.16.5.5 Stamped Concrete Paving Installation
3.16.5.6 Apply 2/3 of dry-shake colored hardener at specified application

rate to freshly floated concrete surface. Bleed water must not be
present during or following application of first and second dry-shake
applications. Do not throw dry-shake colored hardener material;
distribute evenly by hand or mechanical spreader designed to apply
floor hardeners. Mechanical spreader manufacturer as acceptable to
stamped concrete paving manufacturer. As soon as dry-shake material
has absorbed moisture, indicated by uniform darkening of surface,
mechanically float concrete surface a second time, just enough to bring
moisture from base slab through dry-shake color hardener. Immediately
following second floating, apply remaining 1/3 of dry-shake colored
hardener at specified application rate. If applied by hand, broadcast in
opposite direction of first application for a more uniform coverage. If a
mechanical spreader is used, apply in same manner as previously
described. As soon as dry-shake material has absorbed moisture,
mechanically float concrete surface a third time. Do not add water to the
surface. Begin imprinting operations immediately after applying dry-
shake colored hardener, according to manufacturer‘s written
instructions, including application of powder antiquing release agent.
3.16.5.7 Sealing
3.16.5.8 Prior to sealing, the following conditions must be present:
3.16.5.9 Release agent has been removed.
3.16.5.10 Moisture content of concrete is low enough that alkali and other
salts do not become trapped beneath sealer. This will require a
minimum of 28 days subsequent to concrete placement, or longer if
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3.16.5.11 No evidence of free water on concrete surfaces to receive curing

and sealing compound.
3.16.5.12 Seal imprinted concrete with liquid membrane curing and sealing
compounds as recommended by manufacturer. Apply two coats of
specified curing and sealing compound according to manufacturer‘s
written instructions.
3.16.5.13 Protection of Finished Work
3.16.5.14 Prohibit foot or vehicular traffic on the newly imprinted concrete

surface. Protect floor surface from damage throughout remainder of
construction period until Final Acceptance of the work. If a covering
material is necessary, surfaces must remain uncovered for a minimum
of four days after which they may be covered with a new, smooth, non
staining reinforced Kraft curing paper. Plastic sheeting is unacceptable
as a covering material.
3.16.6 STORAGE, HANDLING & DELIVERY
3.16.6.1 Deliver products in original factory unopened, undamaged

packaging bearing identification of product, manufacturer, batch
number, and expiration date as applicable.
3.16.6.2 Store products in a location protected from damage, construction

activity, and adverse environmental conditions according to
manufacturer‘s current recommendations.
3.16.6.3 Imprinting tools must be stored flat, textured face up, with no
objects resting on top. Handle products according to manufacturer‘s
printed instructions.
3.16.6.4 Care must be taken to ensure that the products are not damaged
while loading / unloading and transporting. Cartons must always be
stored with designated side upwards.
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3.16.7.1 Measurement for stamped concrete shall be done in Square

meters correct to two decimal places for area to be imprinted. The
superficial area of paving work shall be considered for measurement
without any deduction for cut-outs measuring up to 0.5 sq. m. in area.
3.16.7.2 This will include the materials, labour, tools, equipment, and
execution.
3.17 PREFORMED JOINT FILLERS AND JOINT SEALING COMPOUND
3.17.1 Preformed joint filler for expansion/isolation joints shall be non-extruding

and resilient type of bitumen impregnated fibres conforming to IS:1838 (Part
I).
3.17.2 Bitumen coat to concrete/masonry surfaces for fixing the preformed

bitumen filler strip shall conform to IS:702. Bitumen primer shall conform to
IS:3384.
3.17.3 Sealing compound for filling the joints above the preformed bitumen filler
shall conform to Grade 'B' as per IS:1834.
3.17.4 WORKMANSHIP
3.17.4.1 The thickness of the preformed bitumen filler shall be as specified

in the respective items of work. CONTRACTOR shall procure the strips
of the desired thickness and width in lengths as manufactured.
Assembly of small pieces/thicknesses of strips to make up the specified
size shall not be permitted.
3.17.4.2 The concrete/masonry surface shall be cleaned free from dust and
any loose particles. When the surface is dry, one coat of bitumen
primer conforming to IS 3384 to be applied over which one coat of
industrial blown type bitumen of grade 85/25 conforming to IS:702 shall
be applied hot by brushing at the rate of 1.20 kg/sq.m. When the
bitumen is still hot, the preformed bitumen filler shall be pressed and
held in position till it completely adheres.
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similarly be applied with one coat of hot bitumen at the rate of 1.20
kg/sq.m.
3.17.4.3 Sealing compound shall be heated to a pouring consistency for

enabling it to run molten in a uniform manner into the joint. Before
pouring the sealing compound, the vertical faces of the concrete joint
shall be applied with a coat of hot bitumen primer conforming to IS:3384
in order to improve the adhesive quality of the sealing compound.
3.17.4.4 Expansion joints between beams/slabs shall be provided with

l00mm wide x 4mm thick mild steel plate at the soffit of RCC
beams/slabs to support and prevent the preformed joint filler from
dislodging. This plate shall be welded to an edge angle of ISA 50 x 50
x 6mm provided at the bottom corner, adjacent to the expansion joint of
one of the beams/slabs, by intermittent fillet welding. Steel surfaces
shall be provided with 2 coats of zinc phosphate primer and 2 coats of
synthetic enamel paint finish.
3.17.5 MEASUREMENT
3.17.5.1 Measurement for the preformed joint filler shal1 be in sq.m correct
to two places of decimal for the specified thickness as per the items of
work. Measurement for applying the bitumen coat to concrete/masonry
surfaces shall be in sq.m correct to two places of decimal.
Measurement for the joint sealing compound shall be in running metres
correct to two places of decimal for the specified width and thickness as
per the items of work. Measurement for the mild steel corner angle and
plate shall be by weight as per the item of work.
3.18 INDIAN PATENT STONE (IPS) FLOORING
3.18.1 MATERIAL
3.18.1.1 Material shall be 10 mm down clean, well graded, hard, approved

granite/basalt /good sound stone chips and clean, sharp, coarse sand.
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and fine aggregates used shall conforming to IS383. Cement shall

conform to IS456.
3.18.2 WORKMANSHIP
3.18.2.1 For flooring, the base Reinforced cement concrete slab or the
grade slab shall be cleaned of all dirt with water and hard brush. If
required the base surface shall be backed or otherwise roughened to
obtain a good bond. The surface shall be clean, free from grease, oil,
dust, loose particles, etc. and thoroughly soaked with water to prevent
absorption of mixing water from the base course. Before placing the
under bed, any excess standing water shall be mopped out. Before
laying the flooring approval of the Engineer-in-charge shall be obtained
as to the acceptability of the base. No extra payment is admissible for
the preparation of base and the unit rate of flooring shall be inclusive of
preparation of the base. Wherever the level is down, the contractor may
have to fill it up with the base concrete to achieve the specified top level
of the flooring surface. Wherever the level is higher, the contractor may
have to chip/break the concrete to achieve the specified thickness of
the floor topping. The rate quoted for the floor topping shall be firm for
the variation in level of the existing surface upto ±12mm. No extra rate
will be paid for chipping the specified floor topping thickness. Similarly
no extra payment will be made for the extra concrete to be laid for
achieving the top specified level in flooring.
3.18.2.2 The Indian patent stone floor unless otherwise stated, shall have a
total thickness of 50 mm laid in two layers. The under-bed shall consist
of 25mm thick cement concrete with 10 mm to 6mm size stones.The
proportion of the mix shall be 1 part cement, 2 parts sand and 4 parts
stone chips by volume. Second layer 15mm shall be with 6mm down
aggregates of above proportion
3.18.2.3 Water content shall be minimum, sufficient to give a workable

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commencement of laying the under bed, thick cement slurry (cement &
water) shall be given on clean surface and then the under bed layer
shall be laid.
3.18.2.4 The floor shall be cast in panels not exceeding 5 sq.m. in area and
no side more than 2.5 m long. The casting sequence shall be in a
chequered board fashion, no two adjacent panels being cast before the
contraction of the previous one has taken place. The edge of each
panel into which the floor is divided shall be supported by flat bars of
steel or glass strips duly oiled to prevent sticking. The bars shall be
removed before filling in adjoining panels. At least 48 hours shall elapse
before the concreting in the adjacent bay is commenced. After laying,
the underbed shall be leveled, compacted and brought to proper grade
with a screed or float. PVC/Glass floor separator of approved make
shall be used between the panels with the approval of Engineer. Unit
rate quoted shall be inclusive of preparation of base, cement slurry
application, underbed and the topping coat and the finishing including
cost of all labour, tools and materials and the PVC/GLASS separators
between adjacent panels.
3.18.2.5 Final layer of minimum 6 mm thickness shall be laid over the

green underbed and trowelled smooth with a mixture of cement and
sand (1:1 by volume). The underbed and topping shall be completed in
one operation.
3.18.2.6 The topping shall be trowelled smooth to the satisfaction of the

Engineer-in-charge. Any marks of trowel shall be mopped with a soft
cloth to give a clean, even and smooth surface.
3.18.2.7 Unit rate quoted shall be inclusive of preparation of base, cement

slurry application, underbed and the topping coat and the finishing
including cost of all labour, tools and materials and the PVC/GLASS
separators between adjacent panels
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3.18.3.1 Measurement shall be for the plan area of flooring and for the
finished work.
3.19 VACUUM DEWATERED FLOOR
3.19.1 The contractor shall submit full details of the system with catalogues etc. he
proposes to adopt for this work. The contractor shall ensure strict
adherence to all the steps given therein to ensure good quality work.
However, it shall be the contractor's entire responsibility to complete the
works to the satisfaction of the Engineer. The contractor shall mobilize to
the site adequate manpower and all the equipment necessary for this work.
Standby arrangement of equipment and power shall also be made to
ensure uninterrupted work.
3.19.2 WORKMANSHIP
3.19.2.1 After placing the concrete in floor, it shall be properly compacted

using needle vibrators combined with surface vibrator to eliminate voids
and entrapped air. The surface vibrator shall be run at least twice over
the concrete surface. Suction mat shall then be laid over this surface
and the mat is connected to the vacuum pump connected with a suction
hose. Vacuum process should then be started and continued for at
least 20 to 25 minutes, ensuring removal of excess water from concrete
and leaving only that much quantity of water that is required for the
hydration of cement at the end of this stage.
3.19.2.2 The mat and pump shall then be removed and mechanically
operated power floats shall be rotated on the wet concrete surface. The
process shall be repeated and the surface shall be finally finished with
minimum two passes of power trowel.
3.19.2.3 The finished surface shall then be covered with a polythene sheet
the following day after sprinkling water on the surface. Ponding of water
shall be carried out after 2-3 days and the surface shall be kept wet
continuously for at least 21 days. ISSUE
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3.19.3 MEASUREMENT
3.19.3.1 Cost of Concrete item and reinforcement item are included in

respective items of work. Rate covered here shall include cost of
labour, equipment used for vacuum dewatering process only. Rest of
the cost shall be covered in respective items of work. Measurement
shall be for the plan area of flooring and for the finished work.
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4 PLASTERING FOR WALL AND CEILINGS
4.1 GENERAL
4.1.1 This specification covers the general requirements for finishing the
plastered brick / concrete surfaces with Plaster of Paris and other related
works forming a part of this job, which may be required to be carried out
though not specifically mentioned above. The work under this specification
shall consist of furnishing of all tools, plants, labour, materials and
everything necessary for carrying out the work.
precedence.
IS: 63 Whiting for paint and putty.

IS: 1200 Method of measurement of building and civil
engineering works.
IS:1635 Code of practice for field slaking of building lime and
preparation of putty.
IS: 2333 Plaster of Paris for ceramic industry
IS: 6932 Methods of test for building limes
IS 1661 Code of practice for application of cement and cement
lime plaster finishes.
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4.3 POP PUNNING WORKS
4.3.1 MATERIALS
4.3.1.1 The plaster of Paris powder shall conform to the requirements of IS:
2333.
4.3.2 WORKMANSHIP
4.3.2.1 The plaster on masonry surface shall be allowed to dry before the POP
punning is applied.
4.3.2.2 Powder of plaster of Paris shall be mixed with water as specified by

manufacturer to form a thick paste and shall be applied on the plastered
surface.
4.3.2.3 The POP shall be laid and rubbed and finally trowelled to a fine uniform
smooth finish. All unevenness shall be rubbed down from top to bottom
in one operation to eliminate joint marks.
4.4 PUTTY WORKS
4.4.1 MATERIALS
4.4.1.1 Water resistant white cement based putty ideal for use on concrete /
mortar walls (internal and external) and ceiling.
4.4.2 WORKMANSHIP
4.4.2.1 Surface Preparation:All loosely adhered material shall be removed from

the wall surface with the help of emery stone, putty blade or white brush
and clean water. The substrate shall be clean, free from dust, grease
and loose material. Dry and absorbent surfaces shall be moistened with
sufficient quantity of clean water.
4.4.2.2 Mixing of putty:Putty shall be mixed with 30-35% clean water slowly to
make a paste. Mixing shall be continued for 10-15 minutes till a uniform
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4.4.2.3 Application on prepared surface:The first coat shall be applied on

already moistened wall surface from bottom to upward direction
uniformly with the help of putty blade. This would ensure less wastage
and proper finish. After drying of first coat of putty, the surface shall be
rubbed gently with wet sponge or very gently with a putty blade in order
to remove loose particles. The surface shall be allowed to dry for at
least for 3 hours and then second coat of putty shall be applied. The
surface shall be allowed to dry completely.
4.4.2.4 Marks if any shall be removed with the help of moist sponge or the
surface shall be rubbed very gently with putty blade. The surface shall
be allowed to dry completely.
4.4.2.5 Only the required quantity of putty shall be prepared at a time and shall
be used within 2-3 hours of mixing of water. The total thickness of the
coats should be limited to maximum 1.5 mm. If required, to remove
unevenness of surface before applying any kind of paint/ distemper,
walls / ceiling surface shall be leveled gently with very fine water proof
emery paper of not less than 5900 number to get a glossy white
surface.
4.4.2.6 Precautions during application:Utmost care shall be taken for proper

and thorough mixing of putty with hand or mechanical stirrer in order to
get best results. Putty shall be applied over fully cured surface. It is
recommended not to rub putty strongly and harshly with rough emery
paper. This breaks the film formed by putty, thus decreasing its water
repellant properties. The total thickness of the coats shall be limited to
maximum 1.5 mm. In case of fresh concrete/ mortar surface, it is
recommended that two coats of white cement wash be done before
application of putty.
4.4.3.1 Material received at site shall be with original packing and labels. It
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4.4.3.2 Material shall be stored at properly covered dry location and shall be
safe from damage.
4.4.3.3 Storage life should not exceed 6 months.
4.4.4 MEASUREMENT
4.4.4.1 Measurement for white cement based putty work shall be in sq. m
correct to two places of decimal. Unless a separate item is provided for
grooves, mouldings etc., these works are deemed to be included in the
unit rates quoted for putty work.
4.4.4.2 The quantity of work to be paid for under these items shall be
calculated by taking the projected surface of the areas plastered after
making necessary deductions for openings for doors, windows, exhaust
fan openings etc. The actual plaster work carried out on jambs/sills of
windows, openings, etc. shall be measured for payment.
4.5 CEMENT PLASTERING WORK
4.5.1 The proportions of the cement mortar for plastering shall be 1:4 (one part of
cement to four parts of sand) unless otherwise specified under the
respective item of work. Cement and sand shall be mixed thoroughly in dry
condition and then water added to obtain a workable consistency. The
quality of water and cement shall be as per relevant IS. The quality and
grading of sand for plastering shall conform to IS:1542. The mixing shall be
done thoroughly in a mechanical mixer unless hand mixing is specifically
permitted by the ENGINEER. If so desired by the ENGINEER sand shall
be screened and washed to meet the specification requirements. The
mortar thus mixed shall be used as soon as possible preferably within 30
minutes from the time water is added to cement. In case the mortar has
stiffened due to evaporation of water this may be re-tempered by adding
water as required to restore consistency but this will be permitted only upto
30 minutes from the time of initial mixing of water to cement. Any mortar
which is partially set shall be rejected and removed forthwith from the site. ISSUE
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Droppings of plaster shall not be re-used under any circumstances.
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4.5.2 WORKMANSHIP
4.5.2.1 Preparation of surfaces and application of plaster finishes shall

generally confirm to the requirements specified in IS:1661 and IS:2402.
4.5.2.2 Plastering operations shall not be commenced until installation of all

fittings and fixtures such as door/window panels, pipes, conduits etc.
are completed.
4.5.2.3 All joints in masonry shall be raked as the work proceeds to a depth of
l0mm/20mm for brick/stone masonry respectively with a tool made for
the purpose when the mortar is still green. The masonry surface to be
rendered shall be washed with clean-water to remove all dirt, loose
materials, etc., Concrete surfaces to be rendered shall be roughened
suitably by hacking or bush hammering for proper adhesion of plaster
and the surface shall be evenly wetted to provide the correct suction.
The masonry surfaces should not be too wet but only damp at the time
of plastering. The dampness shall be uniform to get uniform bond
between the plaster and the masonry surface.
4.5.3 Interior plain faced plaster - This plaster shall be laid in a single coat of
13mm thickness. The mortar shall be dashed against the prepared surface
with a trowel. The dashing of the coat shall be done using a strong
whipping motion at right angles to the face of the wall or it may be applied
with a plaster machine. The coat shall be trowelled hard and tight forcing it
to surface depressions to obtain a permanent bond and finished to smooth
surface. Interior plaster shall be carried out on jambs, lintel and sill faces,
etc. as shown in the drawing and as directed by the ENGINEER. Rate
quoted for plaster work shall be deemed to include for plastering of all these
surfaces.
4.5.4 Plain Faced Ceiling plaster - This plaster shall be applied in a single coat of
6mm thickness. The proportion of cement mortar shall be 1:3.
4.5.5 Exterior plain faced plaster - This plaster shall be applied in 2 coats. The ISSUE
first coat or the rendering coat shall be approximately 14mm thick. The R4
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rendering coat shall be applied as stipulated as mentioned, except finishing

it to a true and even surface and then lightly roughened by cross scratch
lines to provide bond for the finishing coat. The rendering coat shall be
cured for atleast two days and then allowed to dry. The second coat or
finishing coat shall be 6 mm thick with approved water proofing admixture, if
so specified in the item description. Before application of the second coat,
the rendering coat shall be evenly damped. The second coat shall be
applied from top to bottom in one operation without joints and shall be
finished leaving an even and uniform surface. The mortar proportions for
the coats shall be as specified in the respective item of work. The finished
plastering work shall be cured for atleast 7 days.
4.5.6 Interior plain faced plaster 20mm thick if specified for uneven faces of brick
walls or for random/coursed rubble masonry walls shall be executed in 2
coats.
4.5.7 Exterior Sand Faced Plaster - This plaster shall be applied in 2 coats. The
first coat shall be 14mm thick and the second coat shall be 6mm thick.
However, only approved quality white sand shall be used for the second
coat and for the finishing work. Sand for the finishing work shall be coarse
and of even size and shall be dashed against the surface and sponged.
4.5.7.1 The mortar proportions for the first and second coats shall be as
specified in the respective items of work.
4.5.7.2 Wherever more than 20mm thick plaster has been specified, which is
intended for purposes of providing beading, bands, etc. this work shall
be carried out in two or three coats as directed by the ENGINEER duly
satisfying the requirements of curing each coat (rendering/floating) for a
minimum period of 2 days and curing the finished work for atleast 7
days.
4.5.7.3 In the case of pebble faced finish plaster, pebbles of approved size and
quality shall be dashed against the final coat while it is still green to
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obtain as far as possible a uniform pattern all as directed by the

ENGINEER.
4.5.7.4 Where specified in the drawings, rectangular grooves of the dimensions

indicated shall be provided in external plaster by means of timber
battens when the plaster is still in green condition. Battens shall be
carefully removed after the initial set of plaster and the broken edges
and corners made good. All grooves shall be uniform in width and
depth and shall be true to the lines and levels as per the drawings.
4.5.7.5 Curing of plaster shall be started as soon as the applied plaster has
hardened sufficiently so as not to be damaged when watered. Curing
shall be done by continuously applying water in a fine spray and shall
be carried out for atleast 7 days.
4.5.7.6 When the specification items of work calls for waterproofing plaster the
CONTRACTOR shall provide the waterproofing compound as specified
while preparing the cement mortar. Payment for water-proofing
compound will be made separately if it is not included as a combined
item of work.
4.5.7.7 Where lath plastering is specified, it shall be paid for at the same rate
as for plaster work except that separate payment for metal lath will be
made.
4.5.7.8 For external plaster, the plastering operations shall be commenced

from the top floor and carried downwards. For internal plaster, the
plastering operations for the walls shall commence at the top and
carried downwards. Plastering shall be carried out to the full length of
the wall or to natural breaking points like doors/windows etc.
4.5.7.9 The finished plaster surface shall not show any deviation more than
4mm when checked with a straight edge of 2m length placed against
the surface.To overcome the possibility of development of cracks in the
plastering work following measures shall be adapted. ISSUE
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4.5.7.10 Plastering work shall be deferred as much as possible so that

fairly complete drying shrinkage in concrete and masonry works takes
place.Steel wire fabric shall be provided at the junction of brick masonry
and concrete to overcome reasonably the differential drying
shrinkage/thermal movement. This steel item shall be measured and
paid for separately. Ceiling plaster shall be done, with a trowel cut at its
junction with wall plaster. Similarly trowel cut shall be adopted between
adjacent surfaces where discontinuity of the background exists.
4.5.8 MEASUREMENT
4.5.8.1 Measurement for plastering work shall be in sq.m correct to two places
of decimal. Unless a separate item is provided for grooves, mouldings,
etc., these works are deemed to be included in the unit rates quoted for
plastering work. The quantity of work to be paid for under these items
shall be calculated by taking the projected surface of the areas
plastered after making necessary deductions for openings for doors,
windows, fan openings etc. The actual plaster work carried out on
jambs/sills of windows, openings, etc. shall be measured for payment.
4.6 CEMENT POINTING
4.6.1 The cement mortar for pointing shall be in the proportion of 1:3 (one part of
cement to three parts of fine sand) unless otherwise specified in the
respective items of work. Sand shall conform to IS:1542 and shall be free
hard, clean and durable particles. Sand shall be approved by ENGINEER
and if so directed it shall be washed/screened to meet specification
requirements.
4.6.2 WORKMANSHIP
4.6.2.1 Where pointing of joints in masonry work is specified on

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15mm/20mm deep in brick/stone masonry respectively as the work

proceeds when the mortar is still green.
4.7 Any dust/dirt in the raked joints shall be brushed out clean and the joints shall
be washed with water. The joints shall be damp at the time of pointing.
Mortar shall be filled into joints and well pressed with special steel trowels.
The joints shall not be disturbed after it has once begun to set. The joints of
the pointed work shall be neat. The lines shall be regular and uniform in
breadth and the joints shall be raised, flat, sunk or 'V' as may be specified in
the respective items of work. No false joints shall be allowed.
4.7.1.1 The work shall be kept moist for atleast 7 days after the pointing is
completed. Whenever coloured pointing is to be done, the colouring
pigment of the colour required shall be added to cement in such
proportions as recommended by the manufacturer and as approved by
the ENGINEER.
4.7.2 MEASUREMENT
4.7.2.1 The quantity of work to be paid for under this Item shall be measured in
sq.m correct to two places of decimal by taking the projected surface of
the area pointed after making necessary deductions for openings, etc.
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5 PAINTING WORKS
5.1 GENERAL
5.1.1 This specification covers the general requirements for painting of interior
and exterior plastered brick / concrete surfaces and partition walls with
suitable paints and other related works forming a part of this job, which may
be required to be carried out though not specifically mentioned above. The
work under this specification shall consist of furnishing of all tools, labour,
materials and everything necessary for carrying out the work.
precedence.
IS: 77 Linseed oil, boiled, for paints

IS: 103 Ready mixed paint, brushing, white lead for
priming and general purposes
IS: 133 Enamel, interior (a) under coating (b) finishing
IS: 137 Ready mixed paint, brushing, bituminous, black
lead free acid alkali water and heat resisting.
IS: 168 Ready mixed paint, air drying for general
purposes.
IS: 337 Varnish, finishing interior
IS: 348 French polish
IS: 427 Distemper, dry, colour as required
IS: 428 Distemper, oil emulsion, colour as required
IS: 524 Varnish, finishing exterior, synthetic
IS: 525 Varnish, finishing exterior and general purposes
IS: 712 Specification for building limes ISSUE
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IS: 1200 Part x Ceilings and Linings

IS: 1200 Part xiii White washing, Colour washing, distempering
and other finishes
IS: 2074 Ready mixed paint, air drying, red oxide- zinc
chrome, priming
IS: 2338 Code of practice for finishing of wood and wood
based materials
IS: 2395 Code of practice for painting concrete, masonry
and plaster surfaces
IS: 2932 Specification for enamel, synthetic, exterior type
(a) undercoating, (b) finishing
IS: 2933 Enamel exterior type (a) undercoating, (b)
finishing
IS: 3536 Specification for ready mixed paint, brushing,
wood primer, pink
IS: 5410 Cement paint, colour as required
IS: 5411 Specification for plastic emulsion paint (Parts 1 &
2) for interior
IS: 6278 Code of practice for white washing & colour
washing
IS: 9862 Specification for ready mixed paint, brushing,
bituminous, black, lead-free, acid, alkali, water and
chlorine resisting
IS: 384 Brushes for painting
IS: 1477 Code of practice for painting
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5.3 PAINTING OF CONCRETE MASONRY, PLASTERED SURFACES &

PARTITION WALLS
5.3.1 MATERIALS
5.3.1.1 All paint products shall have no added lead, mercury, chromium,
arsenic and antimony content.
5.3.1.2 Oil bound distemper shall conform to IS: 428. The primer shall be alkali
resistant primer of the same manufacture as that of the distemper.
5.3.1.3 Cement paint shall conform to IS: 5410. The primer shall be a thinned
coat of cement paint.
5.3.1.4 Acrylic emulsion paint shall be of an approved manufacture.
5.3.1.5 Plastic emulsion paint shall conform to IS: 5411.
5.3.1.6 Lead free acid, alkali and chlorine resisting paint shall conform to IS:
9862.
5.3.1.7 All paints shall have low VOC with VOC for non flat (gloss finish) paints
shall be 150g/l and VOC for flat (mat finish) paint shall be 50 g/l.
5.3.1.8 White wash shall be made from good quality fat lime conforming to IS:
712. It shall be slaked at site and mixed with water in the proportion of 5
litres of water to 1 kg of un-slaked lime stirred well to make a thin
cream. This shall be allowed to stand for a minimum period of one day
and strained through a clean coarse cloth. Four kg of gum dissolved in
hot water shall be added to each cu.m of cream. 1.30 kg of sodium
chloride dissolved in hot water shall then be added per 10 kg of lime
used for the white wash to be ready for application.
5.3.1.9 Colour wash shall be made by addition of a suitable quantity of mineral

pigment, not affected by lime, to the prepared white wash to obtain the
shade/tint as approved by the ENGINEER.
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5.3.1.10 All the materials shall be of the best quality from an approved
manufacturer. CONTRACTOR shall obtain prior approval of the
ENGINEER for the brand of manufacture and the colour/shade. All
materials shall be brought to the site of works in sealed containers.
5.3.2 WORKMANSHIP
5.3.2.1 CONTRACTOR shall obtain the approval of the ENGINEER regarding

the readiness of the surfaces to receive the specified finish, before
commencing the work on painting.
5.3.2.2 Painting of new surfaces shall be deferred as much as possible to allow

for thorough drying of the sub-strata.
5.3.2.3 The surfaces to be treated shall be prepared by thoroughly brushing

them free from dirt, mortar droppings and any loose foreign materials.
Surfaces shall be free from oil, grease and efflorescence. Efflorescence
shall be removed only by dry brushing of the growth. Cracks shall be
filled with Gypsum. Workmanship of painting shall generally conform to
IS: 2395.
5.3.2.4 Surfaces of doors, windows etc. shall be protected suitably to prevent

paint finishes from splashing on them.
5.3.3 WHITE WASH - The prepared surfaces shall be wetted and the finish
applied by brushing. The operation for each coat shall consist of a stroke of
the brush first given horizontally from the right and the other from the left
and similarly, the subsequent stroke from bottom upwards and the other
from top downwards, before the first coat dries. Each coat shall be allowed
to dry before the next coat is applied. Minimum of 2 coats shall be applied
unless otherwise specified in the item of work. The dry surface shall present
a uniform finish without any brush marks.
5.3.4 COLOUR WASH - Colour wash shall be applied in the same way as for
white wash. A minimum of 2 coats shall be applied unless otherwise
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uniform finish without any streaks. The finished dry surface shall not show
any signs of peeling/powdery and come off readily on the hand when
rubbed.
5.3.5 CEMENT PAINT - The prepared surfaces shall be wetted to control surface
suction and to provide moisture to aid in proper curing of the paint. Cement
paint shall be applied with a brush with stiff bristles. The primer coat shall
be a thinned coat of cement paint. The quantity of thinner shall be as per
manufacturer's instructions. The coats shall be vigorously scrubbed to work
the paint into any voids for providing a continuous paint film free from
pinholes for effective waterproofing in addition to decoration. Cement paint
shall be brushed in uniform thickness and the covering capacity for two
coats on plastered surfaces shall be 3 to 4 kg/sq.m. A minimum of 2 coats
of the same colour shall be applied unless otherwise specified in the item of
work. At least 24 hours shall be left after the first coat to become sufficiently
hard before the second coat is applied. The painted surfaces shall be
thoroughly cured by sprinkling with water using a fog spray at least 2 to 3
times a day. Curing shall commence after about 12 hours when the paint
hardens. Curing shall be continued for at least 2 days after the application
of final coat. Paint may also be applied using rollers.
5.3.6 OIL BOUND DISTEMPER - The prepared surfaces shall be dry and
provided with one coat of alkali resistant primer by brushing. The surface
shall be finished uniformly without leaving any brush marks and allowed to
dry for at least 48 hours. A minimum of two coats of oil bound distemper
shall be applied unless otherwise specified in the item of work. The first
coat shall be of a lighter tint. At least 24 hours shall be left after the first coat
to become completely dry before the application of the second coat. Broad,
stiff, double bristled distemper brushes shall be used for the work. Paint
may also be applied using rollers.
5.3.7 PLASTIC EMULSION PAINT - The prepared surface shall be dry and
provided with one coat of primer which shall be a thinned coat of emulsion
paint. The quantity of thinner shall be as per manufacturer's instructions. ISSUE
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The paint shall be laid an evenly and smoothly by means of crossing and
laying off. The crossing and laying off consists of covering the area with
paint, brushing the surface hard for the first time over and then brushing
alternately in opposite directions two or three times and then finally
brushing lightly in a direction at right angles. In this process, no brush
marks shall be left after the laying off is finished. The full process of
crossing and laying off constitutes one coat. The next coat shall be applied
only after the first coat has dried and sufficiently become hard which
normally takes about 2 to 3 hours. A minimum of 2 finishing coats of the
same colour shall be applied unless otherwise specified in the item of work.
Paint may also be applied using rollers. The surface on finishing shall
present a flat velvety smooth finish and uniform in shade without any
patches. Paint may also be applied using rollers.
5.3.8 ACRYLIC EMULSION PAINT - Acrylic emulsion paint shall be applied in the
same way as for plastic emulsion paint. A minimum of 2 finishing coats over
one coat of primer shall be provided unless otherwise specified in the item
of work. Paint may also be applied using rollers.
5.3.9 ACID, ALKALI RESISTING PAINT - A minimum of 2 coats of acid/alkali

resisting paint shall be applied over the prepared dry surfaces by brushing.
Primer coat shall be as per manufacturer's instructions.
5.3.10 SYNTHETIC ENAMEL PAINT - The prepared surface shall be dry and
provided with one coat of primer which shall be a thinned coat of enamel
paint. The quantity of thinner shall be as per manufacturer's instructions.
The paint shall be laid on evenly and smoothly by means of crossing and
laying off. The crossing and laying off consists of covering the area with
paint, brushing the surface hard for the first time over and then brushing
alternately in opposite directions two or three times and then finally
brushing lightly in a direction at right angles. In this process, no brush
marks shall be left after the laying off is finished. The full process of
crossing and laying off constitutes one coat. The next coat shall be applied
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normally takes about 2 to 3 hours. A minimum of 2 finishing coats of the

same colour shall be applied unless otherwise specified. Paint may also be
applied using rollers. The surface on finishing shall present a flat velvety
smooth finish and uniform in shade without any patches.
5.3.11 ACRYLIC DISTEMPER - The prepared surfaces shall be dry and provided
with one coat of alkali resistant primer by brushing. The surface shall be
finished uniformly without leaving any brush marks and allowed to dry for at
least 48 hours. A minimum of two coats of acrylic distemper shall be
applied, unless otherwise specified. The first coat shall be of a lighter tint. At
least 24 hours shall be left after the first coat to become completely dry
before the application of the second coat. Broad, stiff, double bristled
distemper brushes shall be used for the work. The operations for brushing
each coat shall be as detailed above.
5.4 PAINTING & POLISHING OF WOOD WORK
5.4.1 MATERIALS
5.4.2 Wood primer shall conform to IS: 3536E.
5.4.3 Varnish shall conform to IS: 337.
5.4.4 French polish shall conform to IS: 348.
5.4.5 Synthetic enamel paint shall conform to IS: 2932.
5.4.6 All the materials shall be of the best quality from an approved manufacturer.
CONTRACTCOR shall obtain prior approval of the ENGINEER for the
brand of manufacture and the colour/shade. All materials shall be brought
to the site of works in sealed containers.
5.4.7 WORKMANSHIP
5.4.7.1 The type of finish to be provided for woodwork, either for painting or
polishing, the number of coats, etc. shall be as specified in the
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5.4.7.2 Primer and finish paint shall be compatible with each other to avoid,
cracking and wrinkling. Primer and finish paint shall be from the same
manufacturer.
5.4.7.3 Painting shall be either by brushing or spraying. CONTRACTOR shall

procure the appropriate quality of paint for this purpose as
recommended by the manufacturer. The workmanship shall generally
conform to the requirements of IS: 2338 (Part I).
5.4.7.4 All the wood surfaces to be painted shall be thoroughly dry and free
from any foreign matter. Surfaces shall be smoothened with abrasive
paper using it across the grains and dusted off. Wood primer coat shall
then be applied uniformly by brushing. The number of primer coats shall
be as specified in the item of work. Stopping as per IS 426 shall be
used to fill up large holes & cracks on the surface. For small holes or
minor cracks, fillers as per IS 110 should be used. Any slight
irregularities of the surface shall then be made up by applying an
optimum coat of filler conforming to IS: 110 and rubbed down with an
abrasive paper for obtaining a smooth surface for the undercoat of
synthetic enamel paint conforming to IS: 2932.
5.4.7.5 Paint shall be applied by brushing evenly and smoothly by means of

crossing and laying off in the direction of the grain of wood. After drying,
the coat shall be carefully rubbed down using very fine grade of sand
paper and wiped clean before the next coat of finishing is applied. At
least 24 hours shall elapse between the applications of successive
coats. Each coat shall vary slightly in shade and this shall be got
approved by the ENGINEER. The number of coats of paint to be
applied shall be as specified in the item of work.
5.4.7.6 All the wood surfaces to be provided with clear finishes shall be
thoroughly dry and free from any foreign matter. Surfaces shall be
smoothened with abrasive paper using it in the direction of the grains
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5.4.7.7 Any slight irregularities of the surface shall be made up by applying an

optimum coat of transparent liquid filler conforming to IS 345. The
Surface when hard shall be rubbed down with fine abrasive paper. All
dust and dirt shall be cleaned and on this surface water or spirit stains
shall be applied to enhance the natural grain or figuring effect of wood.
5.4.7.8 After the surface is dry, a suitable sealer shall be applied to prevent
bleeding of stain and filler into the finish coat. The surface shall be
rubbed down lightly, wiped off and allowed to dry.
5.4.7.9 Over this prepared surface, varnish conforming to IS: 337 shall be
applied by brushing. Varnish should not be retouched once it has begun
to set. Staining if required shall be provided as directed by the
ENGINEER. When two coats of varnish is specified, the first coat
should be a hard-drying undercoat or flatting varnish which shall be
allowed to dry hard before applying the finishing coat. The number of
coats to be applied shall be as per the item of work.
5.4.7.10 For works where clear finish of French polish is specified the
prepared surfaces of wood shall be applied with the polish using a pad
of woollen cloth covered by a fine cloth. The pad shall be moistened
with polish and rubbed hard on the surface in a series of overlapping
circles to give an even finish over the entire area. The surface shall be
allowed to dry before applying the next coat.
5.4.7.11 Finishing shall be carried out using a fresh clean cloth over the
pad, slight dampening with methylated spirit and rubbing lightly and
quickly in circular motions. The finished surface shall have a uniform
texture and high gloss. The number of coats to be applied shall be as
per the item of work.
5.4.8 MOCK-UP
5.4.8.1 The contractor shall prepare and install mock-up samples as per
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5.4.8.2 Mock-up samples shall be of full size and shall be true representation of
actual works to be carried out at site. Mock-ups may be part of
completed work if undisturbed.
shall be intact till issued for use of site.
safe from damage.
5.4.9.3 Paints shall be kept covered at all times and mixing shall be done in
suitable containers.
5.4.9.4 All necessary precautions shall be taken against fire hazards.
5.4.10 MEASUREMENT
5.4.10.1 Measurement for painting works shall be in sq.m correct to two

places of decimal. Actual superficial surface area of wood work
(specification is for wood works shall be measured for payment as per
the respective items of work after making deductions for openings etc.
5.4.10.2 No deduction shall be made for openings up to 0.5 sq.m. of area

nor any extra to be paid for jambs, sills etc..
5.4.10.3 For openings exceeding 0.5 sq.m. but not exceeding 3.0 sq.m.,
deductions shall be made for half the area of openings and no additions
shall be made for jambs, sills etc.
5.4.10.4 For openings exceeding 3.0 sq.m., deductions shall be made for
the whole area and additions shall be made for jambs, sills, soffits etc.
5.4.10.5 No extra payment shall be made for painting etc. done around
openings, wall features like grooves, projections, cornices etc.
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5.4.10.6 Rate quoted shall take into account the provision of necessary
enabling works such as scaffolding, painter's cradle etc.
5.4.10.7 Measurement for painting / polishing of woodwork shall be for the

projected area between out to out of frames and no multiplying factor is
allowed on any account. Rate shall be inclusive of all enabling works.
5.5 PAINTING OF STEEL WORK
5.5.1 For painting of structural steel refer separate M4 specification.
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6 DOORS, WINDOWS AND VENTILATORS
6.1 GENERAL
6.1.1 This specification covers the general requirements for doors, windows and
ventilators and other related works forming a part of this job, which may be
required to be carried out though not specifically mentioned above. The
work under this specification shall consist of furnishing of all tools and
tackles, plants, labour, materials and everything necessary for carrying out
the work.
precedence.
IS: 287 Recommendation for maximum permissible moisture

contents of timber used for different purposes
IS: 303 Plywood for general purpose
IS: 419 putty for use on window frames
IS: 710 Marine plywood
IS: 733 Wrought aluminum and aluminum alloys, bars, rods
and sections for general engineering purposes.
IS: 1003 Timbered paneled and glazed shutters for doors and
windows.
IS: 1038 Steel doors, windows and ventilators
IS: 1081 Code of practice for fixing and glazing of metal (steel
and aluminum) doors, windows and ventilators
engineering works.
IS: 1361 Specification for steel windows for industrial buildings ISSUE
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IS: 1477 Code of practice for painting of ferrous metals in

buildings
IS: 1911 Schedule of unit weights of building materials
IS: 1659 Block boards
IS: 1868 Anodic coating on aluminum and its alloys
IS: 1948 Specification for aluminum doors, windows and
ventilators
IS: 1949 Specification for aluminum windows for industrial
buildings
IS: 2074 Ready mixed paint, air drying, red oxide zinc chrome,
priming
IS: 2191 Wooden flush doors (cellular and hollow core type),
plywood faced panels, particle board faced panels.
IS: 2202 Wooden flush doors (solid core type), plywood
faced panels, particle board faced panels.
IS: 2835 Flat transparent sheet glass
IS: 3614 Metallic and non-metallic fire check doors -
resistance test and performance criteria.
IS: 4020 Methods of test for wooden flush doors
IS: 4021 Timber door, window and ventilator frames
IS: 4351 Steel door frames
IS: 5437 Figured rolled and wired glass
IS: 5523 Methods of testing anodic coatings on aluminum
IS: 6248 Metal Rolling shutters and rolling grills
IS: 7452 Hot rolled steel sections for doors, windows and
ventilators.
IS: 13871 Powder Coatings
IS: 15380 Moulded raised high density fibre (HDF) doors.
IS: 15931 Solid panel foam UPVC door shutters
BS: 476 Fire tests for building materials and structures.
NFPA 80 Standards for fire doors and other opening
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6.3 WOOD WORK IN DOORS, WINDOWS, & VENTILATORS
6.3.1 MATERIALS
6.3.1.1 Timber to be used shall be first class Teak wood as per IS: 4021.
Timber shall be of the best quality and well seasoned by a suitable
process before being planed to the required sizes. The maximum
permissible moisture content shall be from 10 to 16 percent for timber
50mm and above in thickness and 9 to 14 percent of timber less than
50mm in thickness for different regions of the country as stipulated In
IS: 287. Timber shall be close grained, of uniform colour and free from
decay, fungal growth, boxed heart, pitch pockets or streaks on the
exposed edges, borer holes, splits and cracks.
6.3.1.2 Flush door shutters of the solid core type with plywood face panels shall
conform to IS: 2202 (Part 1) and with particle board/hard board face
panels shall conform to IS: 2202 (Part 2).
6.3.1.3 Transparent sheet glass shall conform to the requirements of IS: 2835.
Wired and figured glass shall be as per IS: 5437.
6.3.1.4 Builder's hardware of fittings and fixtures shall be of the best quality
from approved manufacturers.
6.3.2 WORKMANSHIP
6.3.2.1 The workmanship and finish of wood work in doors, windows,

ventilators and partitions shall be of a very high order. CONTRACTOR
shall ensure that work is executed in a professional manner by skilled
carpenters for good appearance, efficient and smooth operation of the
shutters.
6.3.2.2 All works shall be executed as per the detailed drawings and/or as
6.3.2.3 All members of the door, window, and ventilator shall be straight without
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angle shall be checked from the inside surfaces of the respective

members of the frame.
6.3.2.4 Frames shall have mortise and tenon joints which shall be treated with
an approved adhesive and provided with metal or wood pins. The
vertical members of the door frame shall project 50 mm below the
finished floor level with a spacer bar. The finished dimension of frames
shall be rebated on the solid for keying with the plaster and for receiving
the shutters. The depth of rebate for housing the shutter shall be 15
mm. The size of the frames shall be as specified in the respective items
of work. The workmanship shall generally conform to the requirements
specified in IS: 4021.
6.3.2.5 The face of the frames abutting the masonry or concrete shall be
provided with a coat of coal tar.
6.3.2.6 Three/sufficient numbers of hold fasts using 25 mm x 6 mm mild steel

flats 225 long with split ends shall be fixed an each side of door and
window frames, one at the centre and the other two at 300 mm from the
top and bottom of the frame. For window and ventilator frames less
than 1 m in height, two hold fasts on each side shall be fixed at quarter
points.
6.3.2.7 Timber panelled shutters for doors, windows and ventilators shall be
constructed in the form of framework of stiles and rails with panel
insertion. The panels shall be fixed by either providing grooves in the
stiles and rails or by beading. Glazing bars shall be as detailed in the
drawings. The stiles and rails shall be joined by mortise and tenon joints
at right angles. All members of the shutter shall be straight without any
warp or bow and shall have smooth, well planed faces at right angles to
each other. The right angle for the shutter shall be checked by
measuring the diagonals and the difference shall not be more than + 3
mm. Timber panels made from more than one piece shall be jointed
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reinforced with metal dowels. The workmanship shall, generally

conform to the requirements specified in IS: 1003 (Parts 1 & 2).The
thickness of the shutter, width/thickness of the stiles/rails/panel type
shall be as indicated in the bid drawings/item of work. Marine plywood
panels conforming to IS: 710 shall be used for doors where specified.
6.3.2.8 Details of the wooden flush door shutters, solid core type with specific
requirement of the thickness, core, face panels, viewing glazed panel,
Venetian louver opening, teak wood lipping etc. shall be as indicated in
the respective items of work. Panels of shutter shall be of marine
plywood conforming to IS: 710, if so specified in the item of work. Flush
door shutters shall be from reputed manufacturers and CONTRACTOR
shall submit test results as per IS: 4020, if so desired by the
ENGINEER.
6.3.2.9 The material of the fittings and fixtures either of chromium plated steel,
cast brass, copper oxidized or anodized aluminum shall be as specified
in the item of work. The number, size and type of the fittings and
fixtures shall be as indicated in the drawings/item of work.
6.3.2.10 Wood work shall not be provided with the finishes of painting,
galvanizing etc. unless it has been approved by the ENGINEER. The
type of finish and the number of coats shall be as stipulated in the
respective items of work. Preparation of the wood surface and
application of the finishes shall be as per Painting and Polishing of
wood works.
6.3.2.11 Any carpentry work which shows defects due to inadequate

seasoning of the timber or bad workmanship shall be removed and
replaced by CONTRACTOR with work as per specification
requirements, at no extra cost to the OWNER.
6.4 STEEL DOORS. WINDOWS AND VENTILATORS
6.4.1 MATERIALS ISSUE

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6.4.1.1 Hot rolled steel sections for the fabrication of steel doors, windows and
ventilators shall conform to IS: 7452, which are suitable for single
glazing.
6.4.1.2 Pressed steel door frames for steel flush doors shall be out of 1.25 mm
thick mild steel sheets of profiles as per IS:4351.
6.4.2 WORKMANSHIP
6.4.2.1 All steel doors, windows and ventilators shall be of the type as specified
in the respective items of work and of sizes as indicated in the
drawings. Steel doors, windows and ventilators shall conform to the
requirements as stipulated in IS: 1038. Steel windows shall conform to
IS: 1361, if so specified.
6.4.2.2 Doors, windows and ventilators shall be of an approved manufacture.

Fabrication of the units shall be with rolled sections, cut to correct
lengths and mitered. Corners shall be welded to form a solid fused
welded joint conforming to the requirements of IS: 1038. Tolerance in
overall dimensions shall be within  1.5mm. The frames and shutters
shall be free from warp or buckle and shall be square and truly plane.
All welds shall be dressed flush on exposed and contact surfaces.
Punching of holes, slots and other provisions to install fittings and
fixtures later shall be made at the correct locations as per the
requirements. Samples of the units shall be got approved by the
ENGINEER before further manufacture/purchase by the
CONTRACTOR.
6.4.2.3 Type and details of shutters, hinges, glazing bar requirement,

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described in the respective items of work and/or as shown in the

drawings for single or composite units.
6.4.2.4 For windows with fly proof mesh as per the item of work, rotor operator
arrangement, for the operation of the glazed shutters from the inside
shall be provided.
6.4.2.5 Pressed steel door frames shall be provided with fixing lugs at each
jamb, hinges, lock-strike plate, mortar guards, angle threshold, shock-
absorbers of rubber or similar material as per the requirements of
IS:4351. Pressed steel door frames shall be fixed as 'built-in', as the
masonry work proceeds. After placing it plumb at the specified location,
masonry walls shall be built up solid on either side or each course
grouted with mortar to ensure solid contact with the door frame, without
leaving any voids. Temporary struts across the width shall be fixed,
during erection to prevent bow/sag of the frame.
6.4.2.6 Door shutters of flush welded construction shall be 45mm thick,

fabricated with two outer skins of 1.25mm thick steel sheets, l.00mm
thick steel sheet sufferers and steel channels an all four edges. Double
shutters shall have meeting stile edge bevelled or rebated. Provision of
glazed viewing panel, louvers shall be made as per the item of work
and/or drawings. Shutters shall be suitably reinforced for lock and other
surface hardware and to prevent sagging/twisting. Single sheet steel
door shutters shall be fabricated out of 1.25mm thick steel sheets, mild
steel angles and stiffeners as per the drawings.
6.4.2.7 Doors, windows and ventilators shall be fixed into the prepared
openings. They shall not be 'built-in' as the masonry work proceeds, to
avoid distortion and damage of the units. The dimensions of the
masonry opening shall have l0mm clearance all-round the overall
dimensions of the frame for this purpose. Any support of scaffolding
members on the frames/glazing bars is prohibited.
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6.4.2.8 Glazing of the units shall be either with flat transparent glass or
wired/figured glass of the thickness as specified in the item of work. All
glass panels shall have properly squared corner and straight edges.
Glazing shall be provided on the outside of the frames.
6.4.2.9 Fixing of the glazing shall be either with spring glazing clips and putty
conforming to IS: 419 or with metal beads. Pre-formed PVC / VINYL or
rubber gasket shall be provided for fixing the beads with concealed
screws. The type of fixing the glazing shall be as indicated in the item of
work and/or in drawings.
6.4.2.10 Steel doors, windows and ventilators shall be provided with finish
of either painting as specified or shall be hot dip galvanized with
thickness of zinc coating as stipulated all as described in the respective
items of work.
6.4.2.11 The material of the Builders hardware of fittings and fixtures of

chromium plated steel, cast brass, brass copper oxidized or anodized
aluminum shall be as specified in the item of work. The number, size
and type of fittings and fixtures shall be as in the bid drawings/item of
work.
6.4.2.12 Installation of the units with fixing lugs, screws, mastic caulking
compound at the specified locations shall generally conform to the
requirements of IS:1081. Necessary holes etc required for fixing shall
be made by the CONTRACTOR and made good after installation.
Workmanship expected is of a high order for efficient and smooth
operation of the units.
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6.5 ALUMINUM DOORS, WINDOWS, & VENTILATORS
6.5.1 MATERIALS
6.5.1.1 Aluminum alloy used in the manufacture of extruded sections for the
fabrication of doors, windows, ventilators shall conform to designation
63400 WP of IS:733.
6.5.1.3 Builder's hardware of fittings & fixtures shall be of the best quality from
approved manufacturers.
6.5.2 WORKMANSHIP
6.5.2.1 All aluminum doors, windows, and ventilators shall be of the type as
specified in the respective items of work and of sizes as indicated in the
drawings. The doors, windows, ventilators shall conform to the
requirements of IS: 1948. Aluminum windows, shall conform to IS:
1949, if so specified.
6.5.2.2 All aluminum units shall be supplied with anodized/powder coated

finish. The minimum anodic film thickness shall be 0.015 mm.
6.5.2.3 Doors, windows and ventilators shall be of an approved manufacture.

Fabrication of the units shall be with the extruded sections, cut to
correct lengths, mitered and welded at the corners to a true right angle
conforming to the requirements of IS: 1948. Tolerance in overall
dimensions shall be within + 1.5mm. The frames and shutters shall be
free from warp or buckle and shall be square and truly plane. Punching
of holes, slots and other provisions to install fittings or fixtures later shall
be made at the correct locations, as per the requirements.
6.5.2.4 Aluminum swing type doors, aluminum sliding windows, partitions shall
be as described in the item of work and/or bid drawings which indicates
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components and weight per running meter of the extruded sections to

be adopted.
6.5.2.5 IS:1948 and IS:1949 referred to incorporates the sizes, shapes,

thicknesses and weight per running meter of extruded sections for the
various components of the units. However, new sizes, shapes,
thicknesses with modifications to suit snap-fit glazing clips etc. are
continuously being added by various leading manufacturers of extruded
sections, which are available in the market. As such, the sections of the
various components of the unit proposed by the CONTRACTOR, will be
reviewed by the ENGINEER and will be accepted only if they are equal
to or marginally more than that specified in the codes/ item of works.
6.5.2.6 The framework of the partitions with mullions and transoms shall be
with anodized/powder coated aluminum box sections of dimensions as
per the item of work. Anodized/powder coated Aluminum box sections
shall be in-filled with timber of class 3 (silver oak or any other
equivalent) as per IS:4021. Panels of double/single glazing/plywood
shall be fixed as per details indicated in the drawing. Partitions shall be
fixed rigidly between the floor and the structural columns/beams
including provision of necessary shims for wedging etc. Finished work
shall be of rigid construction, erected truly plumb to the lines and levels,
at locations as per the construction drawings.
6.5.2.7 Specific provisions as stipulated for steel doors, windows, ventilators

shall also be applicable for this item work. Glazing beads shall be of the
snap-fit type suitable for the thickness of glazing proposed as indicated
in the item of work.
6.5.2.8 A layer of clear transparent lacquer shall be applied on aluminum

sections to protect them from damage during installation. This lacquer
coating shall be removed after the installation is completed.
6.6 METAL ROLLING SHUTTERS AND ROLLING GRILLS

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6.6.1 MATERIALS
6.6.1.1 Metal Rolling shutters and rolling grills shall be of an approved

manufacture, conforming to the requirements specified in IS: 6248.
6.6.1.2 The type viz. self coiling type (manual) for clear areas up to 12 sq.m,
gear operated type (mechanical) for clear areas up to 35 sq.m and
electrically operated type for areas up to 50 sq.m shall be as specified
in the IS Code 6248. Mechanical type shall be suitable for operation
from both inside and outside with the crank handle or chain gear
operating mechanism duly considering the size of wall/column.
Electrical type shall also be provided with a facility for emergency
mechanical operation.
6.6.2 WORKMANSHIP
6.6.2.1 Rolling shutters / grill shall be supplied duly considering the type,
specified clear width/height of the opening and the location of fixing as
indicated in the drawings.
6.6.2.2 Rolling Shutter curtain shall be built-up of interlocking laths 75mm width
between rolling centers formed from cold rolled steel strips. The
thickness of the steel strip shall not be less than 0.90 mm for shutters
up to 3.50m width and not less than 1.20 mm for shutters above 3.50 m
width. Each lath section shall be continuous single piece without any
welded joint.
6.6.2.3 Fabrication and assembly of rolling grill curtain shall have the type of
links and other additional requirements as specified in the item of
works.
6.6.2.4 The guide channels out of mild steel sheets of thickness not less than
3.15 mm shall be of either rolled, pressed or built up construction. The
channel shall be of size as stipulated in IS: 6248 for various clear width
of the shutters / grill.
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6.6.2.5 Hood covers shall be of mild steel sheets not less than 0.90mm thick
and of approved shape.
6.6.2.6 Rolling shutters / grill shall be provided with a central hasp and staple
safety device in addition to one pair of lever locks and sliding locks at
the ends.
6.6.2.7 Where a rolling shutter is combined with rolling grill, height of rolling grill
shall be 500mm maximum.
6.6.2.8 All steel components (excepting springs and insides of guide channels)
shall be provided with one coat of zinc chrome primer conforming to IS:
2074 at the time of work.
6.6.2.9 Where galvanizing is called for, the curtain sections, guides, lock plate,
bracket plates, suspension shaft and the hood cover shall be hot dip
galvanized with a zinc coating containing not less than 97.5 percent
pure zinc. The weight of the zinc coating per sq.m shall be as specified
in the item of work.
6.6.2.10 Guide channels shall be installed truly plumb at the specified

location. Bracket plate shall be rigidly fixed with necessary bolts and
holdfasts. Workmanship of erection shall ensure strength and rigidity of
rolling shutter for trouble free and smooth operation.
6.6.2.11 Rolling shutter/grills manufactured by reputed manufacturer as

part of their standard product can also be used, provided the quality
and size of members satisfy the stipulations above.
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6.7 AUTOMATIC SLIDING DOOR
6.7.1 MATERIALS AND WORKMANSHIP
6.7.1.1 These doors shall be from reputed approved manufacturers specialized

in this area of works. However, it shall have following minimum
features.
6.7.1.2 Size of module shall be as specified in the drawing.
6.7.1.3 Size of the frame and material for frames will be decided as per project
requirement.
6.7.1.4 It should consist of microprocessor control unit, monitoring device for

opening and closing, automatic reverse system on contact with
obstruction. In general, it should be operable without the use of any
additional instrumentation or gadgets by the user.
6.7.1.5 The module should be provided with short circuit proof power supply
unit for power rating of 220/240 V, 50/60 Hz. A power point will be
made available at a suitable location by electrical contractor.
6.7.1.6 The door shall have facilities for activation by infrared movement
detector on both sides.
6.7.1.7 Opening and closing speed – 10 to 60 cm/sec/leaf.
6.7.1.8 Creep speed – 3 to 9 cm/sec/leaf
6.7.1.9 Opening time – 0 to 180 sec.
6.7.1.10 Both the fixed and sliding panels shall be made of 12 mm thick
toughened glass with or without etching. It should be provided with all
required fittings and fixtures, digital entry – exit function on the top and
electro- mechanical locking system.
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6.8 UPVC DOORS AND WINDOWS
6.8.1 MATERIALS
6.8.1.1 The UPVC windows shall be made of high quality UPVC profile section
and GI/Aluminum reinforcement.
6.8.1.2 Generally, the UPVC windows shall comprise of main profiles for outer
frames and shutters, beads, coupling mullions, bays and reinforcement.
6.8.1.3 The windows shall be non combustible, non corrosive, shall have good
sound and heat insulation properties, shall withstand harsh weather
conditions and desert conditions and shall not form stains, blisters or
corrosion in salty conditions.
6.8.2 WORKMANSHIP
6.8.2.1 Fabrication and erection of windows shall be done as per the approved
fabrication drawings.
6.8.2.2 Windows shall consist of steel and/or aluminum reinforcement secured

to UPVC profiles at max 100mm from the ends of the reinforcement and
at a spacing of max 400mm c/c between two ends.
6.8.2.3 Reinforcement shall be secured to profiles with self tapping screws.
6.8.2.4 Drainage slots shall be provided in the outer chamber of the profile. All
horizontal members, except heads of the outer frame, shall have
drainage slots of min 5mm wide and 30mm long.
6.8.2.5 EPDM weather seals shall be fitted in the continuous lengths, inserted
in the weather seal grooves. Joints in the vent weather seals shall be
placed at the bottom and at top in the outer frame.
6.8.2.6 Friction stays shall be of high quality stainless steel and nylon
component for improved durability.
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6.8.2.7 Windows shall be provided with necessary hardware as per

manufacturer's details and specification.
6.8.2.8 The workmanship shall be absolutely top class and of international

standards and final finish shall conform to approve sample.
6.8.2.9 Upon delivery, window profiles shall have protective wrapping. On

completion of installation work, the cover shall be removed and
windows shall be cleaned for inspection and approval.
6.8.2.10 Manufacturer's guidelines shall be followed for cleaning the

surface.
6.8.2.11 Contractor shall provide warranty for installed hand railing system
for the period described herein, starting from date of completion of
installation work. When notified in writing from Owner,
contractor/installer shall promptly correct the said deficiencies, without
inconvenience and extra cost to owner.
6.8.3 MOCK-UP
6.8.3.1 The contractor shall prepare and install mock-up samples as per
approved shop drawings.
6.8.3.2 Mock-up samples shall be of full size and shall be true representation of
actual works to be carried out at site. Mock-ups may be part of
completed work if undisturbed.
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6.8.4.1 No doors/windows shall be delivered to the building until weatherproof

storage space is available. Material received at site shall be with
original packing and labeled. It shall be kept intact under lock and key
till issued for use of site.
6.8.4.2 Store finished shop work in weather tight well-ventilated structures or in

space in existing buildings designated.
6.8.4.3 Finished shop work shall not be installed in any room or space where
concrete, masonry, or plaster work is not completed and dry.
6.8.4.4 Contractor shall use all means necessary to protect doors, windows
and associated fittings from damage prior to, during, and after
installation. All damaged items shall be repaired or replaced by the
contractor at no cost to the owner.
6.8.5 MEASUREMENT
6.8.5.1 Measurement for doors, windows, and ventilators shall be in sq.m

correct to two places of decimal.
6.8.5.2 Measurement shall be from out to out of the frames.
6.8.5.3 Rate quoted shall be for all the works including glazing, painting,
builder's hardware of fittings and fixtures as specifically described in the
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7 BUILDER'S HARDWARE / IRONMONGERY
7.1 GENERAL
7.1.1 This specification covers the general requirements for hardware such as
hinges, locks, stays, stoppers, handles etc. for doors, windows, and
ventilators and other related works forming a part of this job, which may be
required to be carried out though not specifically mentioned above. The
work under this specification shall consist of furnishing of all tools, labour,
materials and everything necessary for carrying out the work.
precedence.
IS: 204 Tower bolts (ferrous and non-ferrous metals)

IS: 205 Non-ferrous metal butt hinges
IS: 208 Door handles
IS: 281 Mild steel sliding door bolts for use with padlocks.
Is: 362 Parliament hinges
IS: 1200 Part VII Hardware
IS: 1341 Steel butt hinges
IS: 1823 Floor door stoppers
IS: 2209 Mortise locks (vertical type)
IS: 2681 Non ferrous metal sliding door bolts for use with pad
locks
IS: 3564 Door closers (hydraulically regulated)
IS: 4992 Door handles for mortise lock (vertical type)
IS: 6607 Rebated mortise locks (vertical type)
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IS: 7197 Double action floor springs (without oil check for
heavy doors)
IS: 7534 Mild steel bolts with holders for pad locks
IS: 7881 Glossary of items relating to building hardware
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7.3 MATERIALS AND WORKMANSHIP
7.3.1 All ironmongery shall be of first quality and shall be obtained from an
approved manufacturer. Butt hinges shall be aluminum alloy, stainless steel
or brass as specified with double stainless steel washers.
7.3.2 The size, materials, finishes, type and quality of ironmongery shall be as
described in the schedule of ironmongery.
7.3.3 Unless otherwise shown and/or scheduled in the drawings, the contractor
shall supply and fix all ironmongery as listed in the Schedule of
Ironmongery attached in the project document, complete with fixing screws
of the same material and finish.
7.3.4 Proper sockets shall be provided for all bolts to fix flush in floors, cills and
door/window/ventilator frames. Each lock shall be provided with minimum
two keys and no two locks shall have identical keys, unless specifically
required.
7.3.5 The use of nails for fixing ironmongery will not be permitted. The Contractor
shall hand over all work in a finished state and to the satisfaction of owner.
7.3.6 On completion of all locks, catches and similar items of ironmongery they
are to be properly cleaned, tested and oiled, and all keys are to be clearly
labeled. All locks provided shall be anti theft.
7.3.7 Master-keying, suiting and grouping of locks shall be according to a master

key schedule.
7.4 MOCK-UP
7.4.1 Contractor shall prepare full size mock-up after sample approval for typical
Doors and Windows and install at location approved by owner for final
approval at no extra cost as specified in the Special Conditions of the
Contract.
7.5 STORAGE, HANDLING & DELIVERY

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7.5.1 The material shall be supplied in the manufacturer‘s original packages and
containers with labels intact and legible, including installation instructions,
templates and maintenance manuals, if any.
7.5.2 Packaging of hardware shall be in complete individual sets for each

door/window/ventilator clearly labeled to show intended locations complete
with all required fixings.
7.5.3 Any items or parts which are damaged or defaced or found to be defective
shall be replaced at the Contractor‘s expense before handing over.
7.6 IRONMONGERY
7.6.1 Ironmongery shall be first quality to be obtained from an approved

manufacturer as specified.
7.6.2 The contractor shall submit a schedule of ironmongery for the approval of
the Engineer before placing any supply order. The Engineer‘s approval of
such schedule shall not relieve the contractor from furnishing all items of
hardware required under the contract.
MEASUREMENT
7.6.3 The hardware/ironmongery items shall be measured in numbers.
7.7 MASTER – KEYING
7.7.1 The contractor shall set up the locks for a system of master- keying. Two
change keys shall be furnished for each lockset.
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8 GLASS AND GLAZING
8.1 GENERAL
8.1.1 This part of the specification covers the requirement of providing fitting and
fixing in position of glazing of different thickness comprising of clear float
glass, wired glass, tinted glass, including curtain glass and hermetically
sealed composite double glazing complete with all clips, putty, mastic, etc.
precedence.
IS: 1200 Part XIV Glazing

IS: 419 Putty for use on window frames
IS: 1081 Code of practice for fixing and glazing of metal doors,
windows and ventilators
IS: 2553 Safety glass for general purpose
(Part 1)
IS: 3548 Code of practice for glazing's in buildings
IS: 5623 Determination of co-efficient of linear thermal expansion
IS: 14900 Transparent float glass
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8.3 MATERIALS
8.3.1 All glass and glazing shall have uniform reflective index and free form flaws,
specs and bubbles.
8.3.2 The glass shall be brought to site in the original packing from the
manufacturer and cut to size at site. The cut edges shall be straight and
free from hips, spells or any other damages.
8.3.3 Clear glass shall be float glass and shall be of thickness as specified in the
schedule of items. Properties of float glass shall generally meet the
requirements of IS: 14900.
8.3.4 Wired glass shall be thick rolled glass with centrally embedded wire mesh
of Georgian type conforming to IS: 5437
8.3.5 Composite double glazing shall be made of two 6mm thick clear float glass
on either sides and separated by 12mm air gap. The trapped air shall be
kept dry by means of suitable desiccant. The glass shall be hermetically
sealed. The composite double glazing shall be procured as finished
product.
8.3.6 The curtain glazing shall consist of minimum 8mm thick heat strengthened
glass fixed with framework made of aluminum sections designed as per
structural requirements.
8.3.7 The silicone sealant shall be of best quality and shall be brought to site in
manufacturer's original packing.
8.4 WORKMANSHIP
8.4.1 All glazing clips, putty, mastic etc. shall be provided as required.
8.4.2 All glasses shall be thoroughly cleaned before setting in position. Wherever
required, glass pane shall be held in place by special glazing clips of
approved type. Minimum four glazing clips shall be provided per glass pane
except for large panes where six or more clips shall be used. All holes that
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glazing beads and all other attachments shall be drilled in position. Glass
panes shall be set without springing, and shall be bedded in putty and back
puttied, except where moulding or gasket are provided.. Putty, mastic etc.
shall be smoothly finished to a true even line.
8.4.3 After completing the glazing work, contractor shall remove all dirt, stains,
excess sealants and clean the glass panes and leave the work in perfectly
acceptable condition. All broken, cracked or damaged glass shall be
replaced by new ones without any extra cost to the owner.
8.4.4 The glass must be protected during installation period so that they will not
be damaged by splashing of cement, welding, grinding etc.
8.4.5 Labels, tapes, adhesives, writing with chalk or any other tool shall never be
done on the coating of glazing.
8.4.6 After completion of installation, the glazing shall be immediately washed

with clean water.
8.4.7 When assembling and installing the glazing, the coating shall be positioned
as indicated in the drawing.
8.4.8 Glazing shall be carefully done to avoid the contact with metal frames.
8.5 MOCK-UP
8.5.1 The contractor shall prepare and install mock-up samples as per approved
shop drawings.
8.5.2 Mock-up samples shall be of full size and shall be true representation of
actual works to be carried out at site. Mock-ups may be part of completed
work if undisturbed.
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174
safe from damage.
8.5.3.3 All items shall be protected from dampness both during and after
delivery to site.
8.5.3.4 Partition shall not be installed in any room or space where concrete,
masonry, or plaster work is not completed and dry.
8.5.3.5 Care must be taken to ensure that the frames and panels of partition
works are not damaged while transporting/erection.
8.5.4 MEASUREMENT
8.5.4.1 Glazing shall be measured in sq.m correct to two places of decimal.

Measurement shall be from out to out of the frames. Rate quoted shall
be for all the works including glazing, painting, builder's hardware of
fittings and fixtures as specifically described in the respective items of
work.
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9 PARTITION WORKS
9.1 GENERAL
9.1.1 This specification covers the general requirements for fabrication and
erection of wooden / aluminum / gypsum board partitions and other related
works forming a part of this job, which may be required to be carried out
though not specifically mentioned above. The work under this specification
shall consist of furnishing of all tools, labour, materials and everything
necessary for carrying out the work.
precedence.
IS: 287 Permissible moisture content for timber used for different
purposes.
IS: 303 Plywood for general purpose
IS: 710 Marine plywood
IS: 733 Wrought aluminum and aluminum alloys, bars, rods
and sections for general engineering purposes.
IS: 848 Synthetic resin adhesive for plywood
engineering works.
IS: 1328 Veneered decorative plywood
IS: 1868 Anodic coating on aluminum and its alloys.
IS: 1948 Aluminum doors, windows and ventilators
IS: 1949 Aluminum windows for industrial buildings
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IS: 2191 Plywood face panels
IS: 2542 Method of test for gypsum plaster

IS: 2835 Flat transparent sheet glass
IS: 3144 Methods of test for mineral wool thermal insulation
materials
IS: 3513 Resin treated compressed wood laminates
IS: 3677 Unbonded rock and slag wool for thermal insulation
IS: 4021 Timber door, window and ventilator frames
IS: 5509 Fire retardant plywood
IS: 5523 Methods of testing anodic coatings on aluminum
IS: 8183 Bonded mineral wool
BS: 2972 Methods of test for inorganic thermal insulating
materials
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9.3 WOOD WORK IN PARTITIONS
9.3.1 MATERIALS
9.3.1.1 Timber to be used shall be first class Teak wood as per IS: 4021.
Timber shall be of the best quality and well seasoned by a suitable
process before being planed to the required sizes. The maximum
permissible moisture content shall be from 10 to 16 percent for timber
50mm and above in thickness and 9 to 14 percent for timber less than
50mm in thickness for different regions of the country as stipulated In
IS: 287.
9.3.1.2 Timber shall be close grained, of uniform colour and free from decay,
fungal growth, boxed heart, pitch pockets or streaks on the exposed
edges, borer holes, splits and cracks.
9.3.2 WORKMANSHIP
9.3.2.1 The workmanship and finish of wood work in partitions shall be of a

very high order. CONTRACTOR shall ensure that work is executed in a
professional manner by skilled carpenters for good appearance,
efficient and smooth operation of the shutters.
9.3.2.2 All works shall be executed as per the detailed drawings and/or as
with the sections of dimensions as per the item at work. Panels of
double/single glazing/ plywood shall be fixed as per details indicated in
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9.3.2.4 Partitions shall be fixed rigidly between the floor and structural
columns/beams including provision of necessary shims for wedging etc.
Finished work shall be of rigid construction, erected truly plumb to the
lines and levels, at locations as per the construction drawings.
9.3.2.5 The face of the frames abutting the masonry or concrete shall be
provided with a coat of coal tar.
9.3.2.6 Glazing of partitions shall be with either flat transparent sheet glass or
figured glass. Transparent sheet glass shall be of 'B' quality as per IS:
2835. The thickness and type of glazing to be provided shall be as
specified in the item of work.
9.3.2.7 The material of the fittings and fixtures either of chromium plated steel,
cast brass, copper oxidized or anodized aluminum shall be as specified
in the item of work. The number, size and type of the fittings and
fixtures shall be as indicated in the drawings/item of work.
9.3.2.8 Wood work shall not be provided with the finishes of painting,
galvanizing etc. unless it has been approved by the ENGINEER. The
type of finish and the number of coats shall be as stipulated in the
9.3.2.9 Any carpentry work which shows defects due to inadequate seasoning
of the timber or bad workmanship shall be removed and replaced by
CONTRACTOR with work as per specification requirements, at no extra
cost to the OWNER.
9.4 ALUMINUM PARTITIONS
9.4.1 MATERIALS
9.4.1.1 Aluminum alloy used in the manufacture of extruded sections for the
fabrication of doors, windows, ventilators shall conform to designation
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9.4.1.3 Builder's hardware of fittings & fixtures shall be of the best quality from
approved manufacturers.
9.4.2 WORKMANSHIP
9.4.2.1 All aluminum partitions shall be of the type as specified in the

respective items of work and of sizes as indicated in the drawings.
9.4.2.2 All aluminum units shall be supplied with anodized/powder coated

finish. The minimum anodic film thickness shall be 0.015 mm.
9.4.2.3 Aluminum partitions shall be as described in the item of work and/or bid
drawings which indicates generally the arrangement along with the
overall size of the various components and weight per running meter of
the extruded sections to be adopted.
9.4.2.4 IS:1948 and IS:1949 are referred to incorporate the sizes, shapes,
thicknesses and weight per running meter of extruded sections for the
various components of the units. However, new sizes, shapes,
thicknesses with modifications to suit snap-fit glazing clips etc. are
continuously being added by various leading manufacturers of extruded
sections, which are available in the market. As such, the sections of the
various components of the unit proposed by the CONTRACTOR, will be
reviewed by the ENGINEER and will be accepted only if they are equal
to or marginally more than that specified in the codes/ item of works.
with anodized/powder coated aluminum extruded sections of
dimensions as per the item of work. Anodized/powder coated Aluminum
extruded sections shall be in-filled with timber of class 3 (silver oak or
any other equivalent) as per IS:4021. Panels of double/single
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Partitions shall be fixed rigidly between the floor and the structural
columns/beams including provision of necessary shims for wedging etc.
Finished work shall be of rigid construction, erected truly plumb to the
lines and levels, at locations as per the construction drawings.
9.4.2.6 Specific provisions as stipulated for steel doors, windows, ventilators

shall also be applicable for this item work. Glazing beads shall be of the
snap-fit type suitable for the thickness of glazing proposed as indicated
in the item of work. A layer of clear transparent lacquer shall be applied
on aluminum sections to protect them from damage during installation.
This lacquer coating shall be removed after the installation is
completed.
9.5 GYPSUM BOARD PARTITION
9.5.1 MATERIALS
9.5.1.1 The gypsum board used in partition works shall be of minimum

thickness as specified in IS: 2095 & IS: 2542.
9.5.1.2 GI frame shall include 48mm studs (0.55mm thick having one flange of
34mm and another flange of 36mm made of GI steel) placed at 610mm
c/c vertically, in 50mm thick floor and ceiling channel (0.55m,m thick
having equal flanges of 32mm made of GI steel).
9.5.1.3 Glass wool of density 24Kg/cum shall comply with BS: 476 Part 4,
1970.
9.5.2 WORKMANSHIP
9.5.2.1 Single Skin Partition shall consist of 13mm thick plaster board screw
fixed with 25mm dry wall screw at 300mm c/c to either side of stud
framework. Necessary cut-outs shall be provided in the partition to
receive cable raceways, electrical/HVAC fittings and fixtures, which
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have a flushed look including filling and finishing with jointing

compound, joint paper tape and two coats of drywall top coat suitable
for gypsum board. Glass wool shall be rot proof and odourless. The
moisture content shall be less than 2% in accordance with BS: 2972.
The water absorption shall be less than 2% in accordance with BS:
2972. The gypsum board shall be continued up to true ceiling or shall
be stopped 100mm above false ceiling. The partition shall be finished to
take on wall paper / paint directly by applying suitable base coats, prime
coats etc. complete.
9.5.2.2 Double Skin Partition shall include first skin consist of 13mm thick
tapered edge plaster board screw fixed with 25mm dry wall screw at
300mm c/c to either side of stud framework. Necessary cut-outs shall
be provided in the partition to receive cable raceways, electrical/HVAC
fittings and fixtures, which shall be neatly finished after fixing the
fixtures thereby leaving no gaps. The layer shall be finished to take on
second skin in gypsum board/Plywood/ MDF directly. The first skin of
the partition shall be continued up to true ceiling. Second skin shall
consist of 13mm thick tapered edge plaster board screw fixed with
35mm dry wall screw at 300mm c/c to existing first skin of partition.
Care shall be taken that the joints are staggered to avoid leakage.
Finally square and tapered edges of the boards shall be joined and
finished to have a flush look including filling and finishing with jointing
compound, joint paper tape and two coats of drywall top coat suitable
for gypsum board. The second skin of partition shall be stopped 100mm
above false ceiling. Necessary cut-outs shall be provided in the partition
to receive cable raceways, electrical/HVAC fittings and fixtures, which
shall be neatly finished after fixing the fixtures thereby leaving no gaps.
The partition shall be finished to take on wall paper / paint directly by
applying suitable base coats, prime coats etc. complete.Skirting shall
be provided with 100mm high and 12mm thick commercial plywood
backing fixed to gypsum backing and finished with 1.5mm laminate. ISSUE
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The skirting shall be flushed to the surface of partition in line and level
and 6mm wide groove to be made in the partition at the junction and
inclusive of SS/Aluminum inserted between the groove formed. The
strip shall be glued to the surface with instant glue of approved make.
The stone/tile shall be fixed to the ply by means of approved
adhesive.50mm thick glass wool insulation of density 24 Kg/cum shall
be wrapped in RP tissues as per manufacturer's specifications. Glass
wool shall be non- combustible and shall be chemically inert.
Application shall not cause or accelerate corrosion.
safe from damage.
9.5.3.3 All items shall be protected from dampness both during and after
delivery to site.
9.5.3.4 Partition shall not be installed in any room or space where concrete,
masonry, or plaster work is not completed and dry.
9.5.3.5 Care must be taken to ensure that the frames and panels of partition
works are not damaged while transporting/erection.
9.5.4 MASUREMENT
9.5.4.1 Measurement of partitions shall be in sq.m correct to two places of

decimal.
9.5.4.2 Measurement shall be from out to out of the frames. Rate quoted shall
be for all the works including glazing, painting, builder's hardware of
fittings and fixtures as specifically described in the respective items of
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10 FALSE CEILING WORKS
10.1 GENERAL
10.1.1 This specification covers the general requirements for fabrication and
erection of aluminum / gypsum board false ceilings and other related works
forming a part of this job, which may be required to be carried out though
not specifically mentioned above. The work under this specification shall
consist of furnishing of all tools, labour, materials and everything necessary
for carrying out the work.
precedence.

engineering works.
IS: 1658 Fibre hard boards
10.3 MINERAL FIBRE BOARD FALSE CEILING
10.3.1 MATERIALS
10.3.1.1 The hard fiber board to be used in false ceiling shall be of an

approved manufacture as per IS: 1658 or as approved by the Owner.
10.3.1.2 The fiber boards shall be made from substances compound of

vegetable fibers such as wood pulp, wood chips or shavings bonded by
a synthetic resin. Veneered particle boards shall have a core of particle
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board sandwiched or glued in between two or more veneers on outer

surfaces.
10.3.1.3 The fiber boards shall be fire resistant, termite and insect resistant,
weather resistant, acoustically satisfactory, dimensionally stable, warp-
free, easily workable, treated with anti-fungus chemicals, heat insulated
and of adequate structural strength and should have good surface finish
as approved by the Owner.
10.3.1.4 The size of fiber board ceiling tile shall generally be 600 x 600 x 12
mm thick. All types of boards and ceiling tiles shall be stored flat under
cover at a clean dry place on firm ground. The Contractor should
ensure that boards are not stacked on termite infected, wet or loose
ground. The boards should be always carried on edges.
10.3.1.5 The metal frame work shall be interlocking type and made of
sections of light metal, such as extruded anodized aluminum. The
shape and cross section shall be such as to facilitate proper suspension
and proper fixing of the ceiling boards covering them and shall be
structurally sound and rigid.
10.3.2 WORKMANSHIP
10.3.2.1 The Contractor shall ensure that the frame to support the ceiling is
designed for its structural strength to withstand the weight of ceiling
boards to be fixed, live load of 75 kg/m2, and other loads such as that
of air- conditioning ducts, grills, electrical wiring and lighting fixtures,
thermal insulation, etc. as shown on the drawings. The Contractor shall
also submit a detailed drawing to show the grid work, sizes of grid
members, method of suspension, position of openings for air-
conditioning and lighting, access doors, etc.
10.3.2.2 The metal frame work of extruded anodized aluminum false ceiling
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ways at 600 mm centre to centre. The aluminum false work shall be

suspended from the roof structures by means of aluminum painted steel
hangers at suitable intervals and supported at the walls by means of
extruded aluminum wall angles.
10.3.2.3 In the case of aluminum grid system, boards are just placed into
the frames formed by the main `T' members and the cross members
fitted with the clips for locking the boards. Contractor should take
utmost care so as not to force the boards in position, and a very little
gap is preferable to a tight joint. Fixing fiber boards by adhesives shall
not be permitted unless approved by the Owner. The fiber boards
should be cut with a fine toothed saw, if required.
10.3.2.4 The hard boards shall be conditioned by wetting the screen

surface with clean water by a sponge or brush. The damp boards
should be stacked back to back on flat surface at site for 48 hours and
then fixed immediately. Conditioning if required shall be done as per the
manufacturer's specifications.
10.3.2.5 As the work of false ceiling may be interconnected with the work of
air-conditioning ducts and lighting, the Contractor shall fully cooperate
with other agencies entrusted with the above works and who may be
working simultaneously. The Contractor shall provide necessary
openings, in the false ceiling work for air- conditioning, lighting and
other fixtures. Additional framing, if required, for the above openings
shall also be provided at no extra cost to the Owner. Removable or
hinged type inspection or access trap doors shall be provided at
locations specified by the Owner.
10.4 THERMAL INSULATION OF CEILINGS
10.4.1.1 Thermal Insulation material consisting of boards slabs and rolls of ISSUE
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creating the required design conditions and shall be provided as

indicated in item of works and as shown in the drawings. The insulation
shall be provided after the sample is approved by the Owner.
10.4.1.2 The quoted rate shall include supply, delivery, cutting and fixing of
all materials for covering the roof with thermal insulation material,
including wood pegs, slotted angle, G.I rawl plugs, wood/coach screws,
lacing wire, G.I washers, wire mesh, any covering as stipulated in
schedule of prices and quantities, finishing at all levels and elevation
etc., complete.
10.4.2.2 Material shall be stored at properly covered dry location and shall
be safe from damage.
10.4.2.3 Care must be taken to ensure that the floor tiles are not damaged
while loading / unloading and transporting. Tile packages shall not be
stacked higher than 2m.
10.4.2.4 Cartons must always be stored with designated side upwards.
10.4.3 MEASUREMENT
10.4.3.1 The superficial area of false ceiling shall be measured and paid for
at the unit rate less deductions, if any. Openings in false ceiling which
are less than 0.4 sq. m in area shall not be deducted for the purpose of
payment.
10.4.3.2 The quoted rates shall include supply, delivery and erection of all
materials for covering the ceiling, frame work suspenders or hangers,
anti-termite treatment making openings in false ceiling, extra frame
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work required for the openings, supporting the main members on

masonry walls, levelling and finishing complete.
10.4.3.3 Where moulding or beading is specified, it shall be as per details

shown in drawings and shall be measured in running meters and paid
for separately.
10.4.3.4 Where fire barriers are specified, they shall be as per details
shown in drawings and as directed and shall be measured in square
meters and paid for separately.
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11 TOILET CUBICLES
11.1 GENERAL
11.1.1 Specification applies to steel toilet partitions / cubicles with doors and
hardware for fixing and mounting of the panels as per architect's design,
plans and schedules. The scope of work includes design, supply,
installation and handling except civil works.
precedence.
IS 277 Galvanized steel sheets (plain and corrugated)

IS 1200 Methods of measurement of building and civil
engineering works
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11.3 MATERIALS
11.3.1 All clamps, fittings, accessories should be made out of first grade quality
galvanized steel conforming to IS 316. All products should be made out of
0.6mm (24g) galvanized sheet.
11.3.2 All galvanized steel fittings and accessories should be cleaned,

phosphatized and finished with one coat of epoxy etching primer of 30
microns of polyurethane paint. All panels / doors should be oven baked for
durability and finish.
11.3.3 Pilaster shoes wherever applicable should be of stainless steel of grade

316
11.3.4 The panels and doors should be constructed out of 12mm thick merino
laminate or any other optional material as specified by the architect.
11.3.5 All panels should have a built in feature to be totally sight proof on all four
corners for better privacy. Standard gap of 150mm on sides and on moving
element has to be provided unless otherwise specified or scheduled in the
drawing or layout.
11.3.6 Cubicles should have a provision for mounting of the toilet hardware like
handrails, hinges, locks with indicator, coat hooks, tissue holders and taps
as per scheduled and specified. All panels should be fully protected with the
self adhesive film and to be removed at the handing over of the cubicles
11.3.7 Compartment Depth and Width: As per the drawings
11.3.8 Door Width: As per the drawings.
11.3.9 Height above Floor:As per Vendor Specifications
11.3.10 Door Height: As per Vendor Specifications
11.3.11 Pilaster Height: As per Vendor Specifications
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11.4.1 Measurement for toilet cubicles shall be done in numbers.
11.4.2 The Urinal partition screens shall also be measured in numbers of the
standard sizes as approved.
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12 SANITARY FIXTURES & FITTINGS
12.1 GENERAL
12.1.1 The scope of this section consists of but is not necessarily limited to
installation, testing and commissioning of Sanitary appliances and fixtures
for toilets, Steel, Chromium plated, brass fittings, Stainless steel sinks,
Accessories e.g. towel rods, toilet paper holders, soap dish, towel rails, coat
hooks, hand dryers, mirrors, liquid soap dispensers etc.
12.1.2 Whether specifically mentioned or not the Contractor shall provide for all
appliances and fixtures, all fixing devices, nuts, bolts, screws, hangers as
required.
12.1.3 All exposed pipes within toilets and near appliances/fixtures shall be of
chromium plated brass or copper unless otherwise specified.
precedence.
IS : 771 Specification for glazed fire clay sanitary

(Part 1 to 3) appliances.
IS : 774 Specification for flushing cistern for water
closets and urinals (other than plastic cistern)
IS : 775 Specification for cast iron brackets and supports
for wash basins and sinks
IS : 781 Specification for cast copper alloy screw down
bib taps and stops valves for water services.
IS : 1700 Specification for drinking fountains. ISSUE
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IS : 2548 Specification for plastic seats and covers for

(Part 2) water closets: Part 1 Thermoset seats and
covers.
IS : 2556 Specification for vitreous sanitary appliances
(Part 1) (Vitreous china) :
Part 1 General requirement.
IS : 2556 (Part Specification for vitreous sanitary appliances
2) (vitreous china): Part 2 Specific requirements of
wash-down water closets.
squatting pans.

4) (vitreous china): part 4 specific requirements of
wash basins.
6 Sec 2) (vitreous china): part 6 Specific requirements of
urinals, section 2 half stall urinals.
6 Sec 4) (vitreous china): Part 6 specific requirements of
urinals, section 4 partition slabs.
6 Sec 5) (vitreous china): Part 6 Specific requirements of
urinals, section 5 waste fittings.
6 Sec 6) (vitreous china): Part 6 Specific requirements of
urinals, section 6 water spreaders for half stall
urinals.
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half round channels.
siphoning wash down water closets.

11) (vitreous china): Part 11 Specific requirements for
shower rose.
floor traps.
universal water closets.
IS : 2692 Specification for ferrule for water services
IS : 2717 Glossary of terms relating to vitreous enamelware
and ceramic metal systems
IS : 5961 Specification for cast iron gratings for drainage
purposes.
IS : 8931 Specification for copper alloy fancy single taps,
combination tap assembly and stop valves for
water services.
IS : 9758 Specification for flush valves and fitting for water
closets and urinals.
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12.3 MATERIALS
12.3.1 Water Closet
12.3.1.1 Water Closet shall be wash down or symphonic wash down type
floor or wall mounted set, as shown in the drawings, designed for low
volume flushing from 2-6 liters of water to be flushed by means of a
porcelain flushing cistern or an exposed or concealed type (as detailed
in the drawings or as directed by the Owner‘s Site Representative) 32
mm size CP, brass flush valve with regulator valve.
12.3.1.2 Flush pipe / bend shall be connected to the WC by means of a

suitable rubber adaptor. Wall hung WC shall be supported by CI floor
mounted chair which shall be fixed in a manner as approved by the
Owners/Site Representative.
12.3.1.3 Each WC set shall be so fixed that it remains absolutely stationary

in vertical position without falling down on the WC.
12.3.1.4 Each WC set shall be provided with approved quality of seat,

rubber buffers and chromium plated hinges. Seat shall be so fixed that
it remains absolutely stationary in vertical position without falling down
on the WC.
12.3.1.5 Each WC shall be provided with 110 mm dia (OD) PVC Pan
Connector connecting the ceramic outlet of WC to CI pipe.
12.3.2 Cisterns / Flush Valve
12.3.2.1 Low level flushing cistern (exposed or concealed) shall be

provided for WC with dual flushing facility in specified toilets. Contractor
shall install cistern in accordance to the manufacturer‘s specification to
the satisfaction of the Owner/Site Representative.
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12.3.3 Wash Basin
12.3.3.1 Wash basins shall be white /coloured glazed vitreous china of

size, shape and type specified in the Schedule of Quantities.
12.3.3.2 Each basin shall be provided with painted MS angle or CI brackets

and clips and the basin securely fixed to wall/counter slab. Placing of
basins over the brackets without secure fixing shall not be accepted.
The MS angle shall be provided with two coats of red oxide primer and
two coats of synthetic enamel paint of make, brand and colour as
approved by the Owner‘s Site Representative. The cost of fixing the
basin shall be inclusive of supply and installation of brackets as
described above.
12.3.3.3 Each basin shall be provided with 32mm dia CP waste with
overflow, pop-up waste or rubber plug and CP brass chain as specified
in the Schedule of Quantities.
12.3.3.4 Each basin shall be provided with hot and cold water mixing fitting
or as specified in the Schedule of Quantities. Wash Faucets shall be
sensor controlled and shall have an added aerator to reduce flow to 2.0
LPM.
12.3.3.5 Flow Rate = 2 Liters per minute @ 58 PSI, all others except
private applications. (as per LEED requirement)
12.3.4 Sinks
12.3.4.1 Sinks shall be stainless steel or any other material as specified in

the Schedule of Quantities.
12.3.4.2 Each sink shall be provided with painted MS or CI brackets and

clips and securely fixed. Counter top sinks shall be fixed with suitable
painted angle iron brackets or clips as recommended by the
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and rubber plug with CP brass chain as given in the Schedule of

Quantities. The MS angle shall be provided with two coats of red oxide
primer and two coats of synthetic enamel paint of make, brand and
colour as approved by the Owner‘s site representative.
12.3.4.3 Sanitary fittings for sinks shall be deck mounted or wall mounted
CP swivel faucets with or without hot and cold water mixing fittings as
specified in the Schedule of Quantities. Installation of fittings shall be
measured and paid for separately.
12.3.4.4 Flow Rate = 2 Liters per minute @ 58 PSI, all others except
private applications. (as per LEED requirement)
12.3.5 Janitor's Sink
12.3.5.1 Janitor's sink shall be stainless steel, single bowl type of size as
called for in the Schedule of Quantities, provided with painted R.S. or CI
brackets and clips and securely fixed. Each sink shall be provided with
40mm dia CP waste. Fixing shall be as directed by the Owner‘s Site
Representative. The supply fittings for Janitor's sink shall be wall
mounted type of size as mentioned in Schedule of Quantities.
12.3.6 Drinking Water Fountain
12.3.6.1 Drinking water fountain shall be wall mounting type made of

vitreous china, stainless steel or any other material as given in the
Schedule of Quantities. The drinking water fountain shall be with anti-
squirt bubble less, self closing valve type with automatic volume
regulator. The drinking water fountain shall be provided with an anti-
splash back and integral strainer with 32mm or 40mm cast brass trap.
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12.3.7 Liquid Soap Dispenser
12.3.7.1 Liquid Soap Dispenser shall be wall/counter mounted suitable for

dispensing liquid soaps, lotions, detergents. The cover shall lock to
body with concealed locking arrangement, opened only be key
provided. Liquid soap dispenser body and shank shall be of high impact
resistance material. The piston and spout shall be stainless steel with 1
litre capacity polyethylene container. The valve shall operate with less
than 2.27 Kg (5 lbs) of force.
12.3.8 Hand Drier
12.3.8.1 The hand drier shall be no touch operating type with solid state
time delay to allow user to keep hand in any position. The hand drier
shall be fully hygienic, rated for continuous repeat use (CRU). The
rating of hand drier shall be such that time required to dry a pair of
hands up to wrists is approximately 30 seconds. The hand drier shall be
of wall mounting type suitable for 230 V, single phase, 50 Hz, AC power
supply.
12.3.9 Shower Set
12.3.9.1 Shower set shall comprise of two CP brass concealed stop cocks,
four/five way auto-diverter, adjustable type over-head shower with CP
shower arm, all with CP wall flanges of approved quality all as specified
in the Schedule of Quantities. Bath spout, hand showers and pop up
wastes shall also be provided wherever, specified. Wall flanges shall be
kept clear off the finished wall. Wall flanges embedded in the finishing
shall not be accepted.
12.3.9.2 Flow Rate = < 6.1 Liters per minute @ 58 PSI (as per LEED
requirement)
12.3.9.3 Flow Control Device

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12.3.9.4 Approved / rated flow control fitment in brass body, chrome outer
cover, rated for flow / discharge of the fixture.
12.3.10 Toilet Paper Holder
12.3.10.1 Toilet paper holder shall be white glazed vitreous china or chrome
plated of size, shape and type specified in the Schedule of Quantities.
12.3.10.2 Porcelain toilet paper holder shall be fixed in walls and set in
cement mortar 1:2 (1 cement: 2 coarse sand) and fixed in relation to the
tiling work.
12.3.10.3 The latter (chrome) shall be fixed by means of screws/capping

having finish similar to the toilet paper holder in wall/temper partitions
with rawl plugs or nylon sleeves. When fixed on timber partition, it shall
be fixed on a solid wooden base member provided by the Owner‘s Site
Representative.
12.3.11 Towel Rail
12.3.11.1 Towel rail shall be chromium plated brass or of stainless steel or

powder coated brass of size, shape and type specified in the Schedule
of Quantities.
12.3.11.2 Towel rail shall be fixed with screws/capping having finish similar
to the towel rail in wall with rawl plugs or nylon sleeves and shall
include cutting and making good as required or directed by the Owner‘s
Site Representative.
12.3.12 Urinals
12.3.12.1 Urinals shall be lipped type half stall with glazed vitreous China of
size as called for in the Bill of Quantities.
12.3.12.2 Half stall urinals shall be provided with 15mm dia CP spreader,
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and CP brass screws as recommended by manufacturer complete as

directed by the Owner‘s Site Representative.
12.3.12.3 Flushing for urinals shall be by means of no hand operation,

infrared electric flush valve with complete kit of plumbing, electrical and
electronic items, infrared photo cells, solenoid valve transformer and
electrical connection. The automatic flush sensor plate shall be flush
and press fitted and shall be of high quality mirror polish finish. Each
urinal shall be provided with one flush valve unit.
12.3.12.4 Flush pipes shall be GI pipes concealed in wall chase but with
chromium plated bends at inlet and outlet.
12.3.12.5 Flow Rate = 4.0 Litres per Flush. 8.5 Liters per minute @ 4 Bar 58
PSI, private applications only (as per LEED requirement)
12.3.13 TOILETS FOR THE DISABLED
12.3.13.1 Where specified, in washroom facilities designed to accommodate

physically disabled, accessories shall be provided as directed by the
Owner‘s Site Representative. Stainless steel garb brass of required
size suitable for concealed or exposed mounting and opened non-slip
gripping surface shall be provided in all washroom. The flushing
cistern/valve shall be provided with chromium plated long handles
12.3.13.2 The contractor shall provide all the necessary supporting and
fixing devices to install the sanitary fixtures and fittings securely in
position. The fixing devices shall be rigidly anchored into the building
structure. The devices shall be rust resistant and shall be so fixed that
they do not present an unsightly appearance in the final assembly.
Where the location demands, the Architect may instruct the contractor
to provide chromium plated or other similarly finished fixing devices. In
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12.4 WORKMANSHIP / FABRICATION & ERECTION
12.4.1 All appliances, fixtures and fittings shall be provided with all such
accessories as are required to complete the item in working condition
whether specifically mentioned or not in the Schedule of Quantities,
specifications, and drawings. Accessories shall include proper fixing
arrangements, brackets, nuts, bolts, washers, screws and required
connection pieces.
12.4.2 The sanitary fixtures and fittings shall be installed at the correct assigned
position as shown on the drawings and as directed by the Architect /
Owner‘s Site Representative and shall fully meet with the aesthetic and
symmetrical requirements as demanded by the Architect / Interior Designer
12.4.3 All fixtures and accessories shall be fixed in accordance with a set pattern
matching the tiles or interior finish as per Architect requirements. Wherever
necessary, the fittings shall be centered to dimensions and pattern as called
for.
12.4.4 Fixing screws shall be half round head chromium plated (CP) brass screws,
with CP brass washers unless otherwise specified.
12.4.5 Fixtures shall be installed by skilled workman with appropriate tools

according to the best trade practice.
12.4.6 All appliances, fittings and fixtures shall be fixed in a neat workmanlike
manner true to level and to heights shown on the drawings and in
accordance with the manufacturers‘ recommendations. Care shall be taken
to fix all inlet and outlet pipes at correct positions. Faulty locations shall be
made good and any damage to the finished floor, tiling, plaster, paint,
insulation or terrace shall be made good by the Contractor at his own cost.
Fixtures shall be mounted rigid, plumb and true to alignment.
12.4.7 All materials shall be rust proofed; materials in direct or indirect contact
shall be compatible to prevent electrolytic or chemical (bimetallic) corrosion.
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12.4.8 Wall flanges shall be provided on all walls, floors, columns etc. wherever
supply and disposal pipes pierce through them. These wall caps shall be or
chromium plated brass fittings and the receiving pipes and shall be large
enough to cover the punctures properly.
12.4.9 Sanitary appliances, subject to the type of appliance and specific

requirements, shall be fixed in accordance with the relevant standards and
the following:
12.4.10 Contractor shall, during the entire period of installation and afterwards
protect the appliances by providing suitable cover or any other protection so
as to absolutely prevent any damage to the appliances until handing over
(The original protective wrapping shall be left in position for as long as
possible)
12.4.11 The appliances shall be placed in correct position or marked out in order
that pipe work can be fixed or partially fixed first.
12.4.12 The appliance shall be fixed in a manner such that it will facilitate
subsequent removal if necessary.
12.4.13 The appliance shall be securely fixed. Manufacturer's brackets and fixing
methods shall be used wherever possible. Compatible rust-proofed fixings
shall be used. Fixing shall be done in manners that minimize noise
transmission.
12.4.14 Appliances shall not be bedded (e.g. WC pans, pedestal units) in thick
strong mortar that could crack the unit (e.g. ceramic unit)
12.4.15 Pipe connections shall be made with demountable unions. Pipe work shall
not be fixed in a manner that it supports or partially supports and appliance.
12.4.16 Appliances shall be fixed true to level firmly fixed to anchor or supports
provided by the manufacturer and additional anchors or supports where
necessary.
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12.4.17 Sizes of sanitary fixtures given in the Specifications or in the Schedule of

Quantities are for identification with reference to the catalogues of make
considered. Dimensions of similar models of other makes may very within +
10% and the same shall be provided and no claim for extra payment shall
be entertained NOR shall any payment be deducted on this account.
12.4.18 The contractor shall fix all plumbing fittings such as water faucets, shower
fittings, mixing valves etc. in accordance with manufacturer‘s instructions
and connect to piping system. The contractor shall supply all fixing
materials such as screws, rawl plugs, unions, collars, compression fittings
etc., as required.
12.4.19 Joints / gaps between all sanitary appliances / fixtures and the floor / walls
shall be caulked with an approved mildew resistant sealant, having
antifungal properties, of colour and shade to match that of the appliances /
fixture and the floor / wall to the extent possible.
12.4.20 The contractor shall install all sanitary fixtures and fittings in their final
position in accordance with approved trial assemblies and as shown on
drawings. The installation shall be complete with all supply and waste
connections. The connection between building and piping system and the
sanitary fixtures shall be through proper unions and flanges to facilitate
removal/replacement of sanitary fixtures without disturbing the built in piping
system. All unions and flanges shall match in appearance with other
exposed fittings.
12.4.21 Fixtures shall be mounted rigid, plumb and to alignment. The outlets of
water closet pans and similar appliances shall be examined to ensure that
outlet ends are butting on the receiving pipes before making the joints. It
shall be ensured that the receiving pipes are clear of obstruction. When
fixtures are being mounted, attention shall be paid to the possibility of
movement and settlement by other causes. Overflows shall be made to
ensure that necessary anchoring devices have been provided for
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12.5 SUPPORTING AND FIXING DEVICES
12.5.1 The contractor shall provide all the necessary supporting and fixing devices
to install the sanitary fixtures and fittings securely in position. The fixing
devices shall be rigidly anchored into the building structure. The devices
shall be rust resistant and shall be so fixed that they do not present an
unsightly appearance in the final assembly. Where the location demands,
the Architect may instruct the contractor to provide chromium plated or
other similarly finished fixing devices. In such circumstances the contractor
shall arrange to supply the fixing devices and shall be installed complete
with appropriate vibration isolating pads, washers and gaskets.
FINAL INSTALLATION
12.5.2 The contractor shall install all sanitary fixtures and fittings in their final
position in accordance with approved trial assemblies and as shown on
drawings. The installation shall be complete with all supply and waste
connections. The connection between building and piping system and the
sanitary fixtures shall be through proper unions and flanges to facilitate
removal/replacement of sanitary fixtures without disturbing the built in piping
system. All unions and flanges shall match in appearance with other
exposed fittings.
12.5.3 Fixtures shall be mounted rigid, plumb and to alignment. The outlets of
water closet pans and similar appliances shall be examined to ensure that
outlet ends are butting on the receiving pipes before making the joints. It
shall be ensured that the receiving pipes are clear of obstruction. When
fixtures are being mounted, attention shall be paid to the possibility of
movement and settlement by other causes. Overflows shall be made to
ensure that necessary anchoring devices have been provided for
supporting water closets, wash basins, sinks and other appliance.
12.6 STORING, HANDLING & DELIVERY
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12.6.1 Material received at site shall be with original packing and labels. It shall be
intact till issued for use of site. Material shall be stored at properly covered
dry location and shall be safe from damage.
12.6.2 Care must be taken to ensure that the sanitary fixtures are not damaged
while loading / unloading and transporting. Cartons must always be stored
with designated side upwards.
12.6.3 The contractor shall take every precaution to protect all sanitary fixtures
against damage, misuse, cracking, staining, breakage and pilferage by
providing proper wrapping and locking arrangement till the completion of
the installation.
12.6.4 At the time of handing over, the contractor shall clean, disinfect and polish
all the fixtures and fittings. Any fixtures and fittings found damaged, cracked
chipped stained or scratched shall be removed and new fixtures and fittings
free from defects shall be installed at his own cost to complete the work.
12.7 MEASUREMENTS
12.7.1 Rate for fixing only of sanitary fixtures accessories, CP fittings shall etc.
include all items, and operations stated in the respective specifications and
bill of quantities and nothing extra is payable.
12.7.2 Rates for all items shall be inclusive of cutting holes and chases and
making good the same, CP screws, nuts, bolts and any fixing arrangements
required and recommended by manufacturers, testing and commissioning
and making good to the satisfaction of the Owner‘s Site Representative.
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13 WATER PROOFING WORKS
13.1 GENERAL
13.1.1 Specification applies to water proofing of terrace, basement and toilet slabs
with elastomeric membrane, waterstops, swellable sealant water bars and
water proofing admixtures.
BS 8102 British Standard- Code of practice for protection of below

ground structures against water from the ground
ASTM– Historical Revision Information Standard Specification

for High Solids Content, Cold Liquid-Applied Elastomeric
C836-89
Waterproofing Membrane for Use with Separate
Wearing Course
IS:1200 - Method of measurement of building and civil

engineering works.
IS:1237 - Specification for cement concrete flooring tiles.
IS:2645 - Specification of integral cement water-proofing

compounds.
IS:8543 - Methods of Testing Plastics (Part 4 / Section 1 )
IS:9766 - Flexible PVC compounds – specification
IS:12200 - Code of practice for provision of water-stops at

transverse contraction joints in masonry and concrete
dams.
IS:13182 Waterproofing and damp-proofing of wet areas in

Buildings
IS:13360 Method of testing plastics(Part5-sec-11)
IS:15058 Water stops at transverse contraction joints –

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13.3 DAMP - PROOF COURSE
13.3.1.1 All the walls in a building shall be provided with damp-proof course
to prevent water from rising up the wall. The damp-proof course shall
run without a break throughout the length of the wall, even under the
door or other openings. Damp-proof course shall consist of 50 mm
thick cement concrete of 1:2:4 nominal mix with approved water-
proofing compound admixture conforming to IS: 2645 in proportion as
directed by the manufacturer. Concrete shall be with 10 mm
downgraded coarse aggregates The surface of brick or stone masonry
work shall be levelled and prepared before laying the cement concrete.
Edge of damp proof course shall be straight, even and vertical. Side
shuttering shall consist of steel forms and shall be strong and properly
fixed so that it does not get disturbed during compaction and the mortar
does not leak through. The concrete mix shall be of workable
consistency and shall be tamped thoroughly to make a dense mass.
When the sides are removed, the surface should come out smooth
without honeycoming. Continuity shall be maintained while laying the
cement concrete layer and laying shall be terminated only at the
predetermined location where damp proof course is to be discontinued.
There shall be no construction joints in the Damp Proof Course.
13.3.1.2 The surface of brick/stone masonry work shall be levelled and

prepared before laying the cement concrete. Side shuttering shall be
properly fixed to ensure that slurry does not leak through and is also not
disturbed during compaction. The upper and side surface shall be
made rough to afford key to the masonry above and to the plaster.
13.3.1.3 Damp-proof course shall be cured properly for at least seven days
after which it shall be allowed to dry for taking up further work.
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13.3.2.1 Measurement of damp-proof course shall be in Sq.m. correct to

two places of decimal as actually executed. No separate payment will
be made for formwork.
13.3.2.2 SELECTION OF TYPE OF WATER PROOFING SHALL BE AS

PER BS8102 AND SHALL BE DISCUSSED WITH CLIENT BEFORE
INCLUDING IN THE SPECIFICATION. BELOW MENTIONED
CLAUSES 13.4, 13.5 & 13.6 ARE APPLICABLE FOR ELASTOMERIC
MAMBRANE TYPE WATERPROOFING.
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13.4 TERRACE OR ROOF WATER-PROOFING WITH ELASTOMERIC

MEMBRANE
13.4.1 MATERIALS
13.4.1.1 Material shall be High solids content Polyurethene based cold

liquid applied coatings as per ASTM C836-89 and shall comprise of
urethane pre-polymers extended with flexible material which cure by
reaction with atmospheric moisture and that can be applied with a brush
on concrete surfaces to form a permanent, flexible, seamless
membrane coating after it is cured.
13.4.1.2 The material shall not be diluted. The coating shall have physical
features like high viscosity, minimum 80% solids, high resistance to
impact, abrasion and cracking, superior tensile strength, 500%
elongation and forming a perfectly smooth permanently flexible
seamless membrane which should have good adhesion to roof surface.
It should also be resistant to acid (mild concentrated), alkalis and have
a very low water absorption rate (0.5% max) at ambient temperature
after 7 days. The material shall not be older than 9 months.
13.4.2 WORKMANSHIP
13.4.2.1 The roof shall be sloped with mortar or concrete (M20 grade with
12mm down size aggregates) screed to achieve the specified slope as
per drawing and shall be properly cured before taking up water-proofing
treatment.
13.4.2.2 The roof surface shall be cleaned of all foreign matters by wire
brushing, dusting etc. and shall be made thoroughly dry. All cracks and
voids on the surface shall be filled with mastic sealant, if required. A V-
groove shall be made along the crack line and shall be filled with mastic
sealant.
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13.4.2.3 Over the cleaned surface, a suitable coat of polyurethane primer

@ 5 – 6 sq.m/ litre shall be applied.
13.4.2.4 First coat of elastomeric membrane shall be applied on the primed

surface @ 0.50 kg/sq.m with a minimum average thickness of 0.50 mm.
13.4.2.5 After the first coat is touched dry, second coat @ 0.50 kg/sq.mm
and minimum average thickness of 0.50mm shall be applied. After the
second coat is dry, third coat shall be applied to result in an overall
thickness of 1.5mm.
13.4.2.6 Due to unavoidable circumstances, if application of second coat is

delayed, special primer shall be applied over the entire surface of first
coat and is allowed to dry for 4 to 8 hours before second coat is
applied.
13.4.2.7 It shall be ensured that a concave fillet 75mm in radius is provided

in cement mortar 1:4 at the junction of roof and vertical faces of
masonry or RCC parapet wall or column projections.
13.4.2.8 Water proofing treatment shall be taken on the brick masonry wall
/ parapet / column projection by a minimum of 150 mm along its height.
Groove 75mm wide and 65mm deep in masonry shall be left for tucking
the water proofing treatment. The groove shall be filled with 1:4 cement
mortar for securing the water proofing treatment firmly.
13.4.3 All completed works shall be cleaned to remove any spillage from
chemicals.
13.4.4 For finishing on top, machine made burnt clay flat terracing tiles conforming
to IS 2690 (Part-1) or cement concrete flooring tiles conforming to IS 1237
shall be used and shall be of the size and thickness as specified in the item
of work. Tiles shall be soaked in water for at least one hour before laying.
Bedding for the tiles shall be 12mm thick in cement mortar 1:3. Tiles shall
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pressed and set to plane surface true to slope, using a trowel and wooden
straight edge. They shall be laid with their longitudinal lines of joints truly
parallel and generally at right angles to the direction of run-off gradient.
Transverse joints in alternate rows shall come directly in line with each
other. Transverse joints in adjacent courses shall break joints by atleast 50
mm. The joints shall be completely filled and flush pointed with cement
mortar l:2 mixed with water proofing compound as per manufacturer's
instructions. Curing shall be carried out for a minimum period of seven
days.
13.4.4.1 After completing all the water proofing works over the roof surface
and curing, the works shall be tested against any leakage / soaking of
water below the roof. For this, arrangement shall be made by
Contractor to store minimum 50mm height of water over the roof
surface and shall be maintained for a period of 7 days. If any wet patch
is observed on the ceiling, rectification of water proofing works should
be attended immediately by the contractor. The test should be repeated
till the leakage / soaking through the ceiling completely stops.
13.4.4.2 The contractor shall give guarantee for a minimum period of 10

years against any leakage / soaking through the ceiling, for the quality
of materials supplied and for the good workmanship carried out. The
guarantee should be in writing on a format prepared by owner. In case
of any defect found in the above during guarantee period, it should be
attended to and rectified immediately by the contractor at his own cost
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13.4.5 MEASUREMENT
13.4.5.1 Measurement shall be for the plan area of treatment and for the
finished work. No separate payment shall be made for the fillets and
work as specified on the vertical faces. Cement concrete tiling works or
machine pressed clay tile works shall be paid separately, unless they
are specifically included in the item of works.
13.5 BASEMENT TYPE OF STRUCTURE WATER PROOFING WITH

ELASTOMERIC MEMBRANE
13.5.1 MATERIAL
13.5.1.1 As specified in clause 14.2.1.
13.5.2 WORKMANSHIP
13.5.2.1 Base slab or raft shall be provided over the lean concrete/PCC.
The membrane shall be applied in the similar manner as mentioned in
clause 13.4.2. The top surface of elastomeric memberane shall be
protected by providing 20mm thick mortar ratio 1:4. Protective coating
shall be cured for 3days.
13.5.2.2 The elastomeric membrane for the vertical wall shall be provided
on the outer face exposed to water pressure/earth pressure. The
membrane shall be applied as explained in clause 13.4.2. There shall
be proper continuation of membrane provided below the base slab /raft
and over the outer face of wall. The exposed membrane shall be
protected by providing extruded high density dimpled polyurethane
board.
13.5.3 MEASUREMENT
13.5.3.1 Measurement shall be for the plan area of treatment and for the
finished work. No separate payment shall be made for providing and
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13.6 TREATMENT TO TOILET –WET AREA SLAB
13.6.1 MATERIAL
13.6.1.1 As specified in clause 14.2.1.
13.6.2 WORKMANSHIP
13.6.2.1 After casting the concrete slab, the surface shall be cured for
required period.
13.6.2.2 The inner surface shall be prepared and membrane coating shall
be applied as described above clause 14.2.2. Provisions of IS13182
shall be adopted for making the wet areas watertight.
13.6.2.3 The prepared surface shall be plastered with cement mortar 1:3 –
15 mm thick admixed with – Normal Setting Integral Waterproofing
Compound conforming to IS: 2645, or approved equivalent at 2% by
weight of cement. Surface shall be cured for minimum 7 days.
13.7 WATERSTOPS
13.7.1 MATERIAL
13.7.1.1 The material for the PVC water stops shall be a plastic compound
with the basic resin of polyvinyl chloride and additional resins,
plasticizers, inhibitors, which satisfies the performance characteristics
specified below as per IS:15058. Testing shall be in accordance with
IS:8543 (Part 4/sec1), IS 13360 (Part 5/sec11) and IS 9766..
Tensile strength : 13.8 MPa minimum
Ultimate elongation : 285% minimum
Hardness (Shore A) : 65, minimum
Water absorption : 0.6 maximum
Cold bend temp

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Accelerated extraction
i) Tensile strength : 10.3 MPa minimum
ii) Ultimate elongation : 280% minimum
Effect of Alkali : 7 days
i) Weight increase : 0.25% maximum
ii) Weight decrease : 0.10% maximum
iii) Hardness change : +/- 5 points
Effect of Alkali : 28 days
i) Weight increase : 0.40% maximum
ii) Weight decrease : 0.30% maximum
iii) Dimension change : +/- 1%
13.7.1.2 PVC water stops shall be either of the bar type, serrated with
centre bulb and end grips for use within the concrete elements or of the
surface (kicker) type for external use. The width, type, minimum
thickness and safe hydraulic head requirements shall be as specified in
the individual items of work.
13.7.1.3 PVC water stops shall be of approved manufacture. Samples and

the test certificate shall be got approved by the ENGINEER before
procurement for incorporation in the works.
13.7.2 WORKMANSHIP
13.7.2.1 Waterstops shall be laid as per IS 12,200. It should be cleaned

before placing them in position. Oil or grease shall be removed
thoroughly using water and suitable detergents.
13.7.2.2 Waterstops shall be procured in long lengths as manufactured to

avoid joints as far as possible. Standard L or T type of intersection
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non-standard junctions shall be made by cutting the pieces to profile for

jointing. Lapping of waterstops shall not be permitted. All jointing shall
be of fusion-welded type as per manufacturer‘s instructions.
13.7.2.3 Waterstops shall be placed at the correct location/level and

suitably supported at intervals with the reinforcement to ensure that it
does not deviate from its intended position during concreting and
vibrating. Care shall also be taken to ensure that no honey-combing
occurs because of the serrations/end grips, by placing concrete with
smaller size aggregates in this region. Projecting portions of the
waterstops from concrete already poured shall be thoroughly cleaned of
all mortar/ concrete coating before resuming further concreting
operations. The projecting waterstop shall also be suitably supported at
intervals with the reinforcement to maintain its intended position during
concreting so as to ensure that it does not bend leading to formation of
pockets. In addition, smaller size aggregate shall be used for
concreting in this region also.
13.7.3 MEASUREMENT
13.7.3.1 Measurement shall be in running metres correct to two places of

decimal. No separate payment shall be made for joints or intersection
pieces.
13.8 SWELLABLE SEALANT WATER-BARS
13.8.1 MATERIAL
13.8.1.1 Material shall be swellable polyurethane /synthetic elastomeric

strips
13.8.2 WORKMANSHIP
13.8.2.1 Construction joint surface shall be cleaned and swellable water ISSUE
bar shall be placed in the grove or fixed with adhesive and cured as R4
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per the manufacturer instruction/specification. before placement of next

layer of concrete.
13.8.3 MEASUREMENT
13.8.3.1 Measurement shall be in running meters correct to two decimal

places. No separate payment shall be made for joints or intersection
pieces.
13.9 WATER-PROOFING ADMIXTURE
13.9.1 Water-proofing admixture shall conform to the requirements of IS:2645 and

shall be of approved manufacture. The admixture shall not contain calcium
chloride. The quantity of the admixture to be used for the works and
method of mixing etc. shall be as per manufacturer's instructions and as
directed by the Engineer. Payment shall be made for the actual quantity of
such admixture used unless it is already covered in the rate for the relevant
item of work.
13.10 INTEGRAL CEMENT BASED WATER PROOFING TREATMENT WITH

BRICK BAT COBA
13.10.1 General: Before taking up the water proofing work the construction of
parapet walls, including finishing should be completed. Similarly, the
ancillary items like haunches, khurras, grooves to tack the fibre cloth layer,
fixing up of all down take pipes, water pipes and electric conduits etc.
should be completed and no such work should be allowed on the area to be
treated during the progress of water proofing treatment or even later.
13.10.1.1 Preparing the Surface: The surface of the slab should be roughened
by scrapping when the slab concrete is still green, however, the
surface need not be hacked. In case the slab is already cast and
surface fairly finished, the same shall be cleaned neatly of all mortar
droppings, loose materials etc with brooms/cloth.
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13.10.1.2 Providing and Laying of Slurry under Base Coat The quantity of
water required to prepare the slurry with 2.75 kg. of blended cement
to be painted over an area of 1 sq m. Depending upon the area of
surface that has to be covered, the required quantity of slurry should
be prepared using 2.75 kg. blended cement + water per sq m. area
to be covered, taking particular care to see that only that much
quantity of slurry shall be prepared which can be used within half an
hour of preparation i.e. before the initial setting time of cement. Page
15 of 42 The prepared slurry shall be applied over the dampened
surface with brushes very carefully, including the joints between the
floor slab and the parapet wall, holes on the surfaces, joints of pipes,
masonry/concrete etc. The application of the slurry should continue
upto a height of 300 mm on the parapet wall. Slurry should also be
applied upto a height of 150 mm over pipe projections etc.
13.10.1.3 Laying Base Coat 20 mm thick Immediately after the application of

slurry and when the application is still green, 20 mm thick cement
plaster as base coat with cement mortar 1:5 (1 blended cement: 5
coarse sand) shall be evenly applied over the concrete surface taking
particular care to see that all the corners and joints are properly
packed and the application of the base coat shall be continued upto a
height of 300 mm over the parapet wall.
13.10.1.4 Laying Brick Bat Coba: Brick bat of size 25 mm to 115 mm out of well
burnt bricks shall be used for the purpose of brick bat coba. The brick
bats shall be properly dampened for six hours before laying. Brick
bats shall be laid to required slope/gradient over the base coat of
mortar leaving 15-25 mm gap between two bats. Cement mortar 1:5
(1 blended cement: 5 coarse sand) shall be poured over the brick
bats and joints filled properly. Under no circumstances dry brick bats
should be laid over the base coat. The haunches/gola at the junction
of parapet wall and the roof shall be formed only with brick bat coba. ISSUE
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initial set there will be no necessity of applying cement slurry over the
base coat before laying the brick bat coba. However, if the brick bat
coba is to be laid on the subsequent day, cement slurry prepared as
described in clause 5.2.2 shall be applied over the top surface of the
base coat, then only the brick bat coba shall be laid.
13.10.1.5 Application of Slurry over Brick Bat Coba: After two days of curing of
brick bat coba cement slurry shall be applied on the surface of brick
bat coba The application of slurry shall cover the haunches/gola, and
the remaining small portion of parapet wall and also inside the
groove .
13.10.1.6 Laying Finishing Layer (Protective Coat) Immediately on applying the

cement slurry over the surface of the brick bat coba and when the
slurry applied is still green, the fiber glass cloth shall be spread
evenly on the surface without any kink & pressed to see that no air
spaces exist. The fiber glass cloth shall be taken up to a height of
300 mm on parapet walls & tucked in the groove specially prepared
at that height. 20 mm thick layer of cement plaster, without leaving
any joints shall be applied with cement mortar 1:4 (1 blended
cement: 4 coarse sand) over the entire fibre glass cloth including the
haunches/gola and the small portion on the parapet wall. The groove
in the parapet wall over the haunches shall also be filled neatly
packing the mortar firmly in the groove. The surface of the finishing
layer (protective coat) shall be neatly finished with cement slurry. The
finished surface shall be allowed to dry for a while and then pattern of
300 mm x 300 mm groove, 8 mm deep shall be made over the entire
surface.
13.10.1.7 Providing and Laying of Fibre Glass Cloth The fiber glass cloth shall
be of approved brand and shall be thin, flexible uniformly bonded mat
composed of chemically resistant borosilicate glass fibre distributed
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thermosetting resin. Immediately on applying the slurry on a

sufficiently workable area, when the slurry applied is still green, the
fiber glass shall be spread evenly on the surface without any kink
and pressed in such a way that no air spaces exist. The fiber glass
cloth shall be taken upto a height of 30 cm on parapet walls and
tucked in the groove specially prepared at that height. A minimum
overlap of 100 mm width shall be provided when the fiber cloth has to
be joined. The joining of 100 mm overlap shall be done with the
same slurry used for the application on surface as first layer. The
fiber cloth shall also be extended upto a height of 100 mm over pipes
projecting from the surface.
13.10.1.8 Curing and Testing the Treatment The entire surface thus treated
shall be flooded with water by making kiaries with weak cement
mortar, for a minimum period of two weeks.
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13.11 WATER PROFING WITH BITUMEN FELT:
13.11.1.1 Hessian based tar felt is the most common product for water proofing
on the new Roofs. These felts use hessian as the barrier medium for
bitumen and bituminous Compound. Bitumen felts are classsified as
Type 1, 2 or 3 depending on type of base used in their manufacture
and the uses for which the felts are suited. Grades refer to minimum
weight of bitumen felt. The bitumen felt should be laid over finished
roof surface of slope not flatter than 1 in 120.
13.11.1.2 In normal weather conditions the treatment should consist of 4

courses as under:-
- Hot applied bitumen @ 1.2-1.464 Kg/Sqm.
- Hessian base self- finished felt type 3 Grade I.
- Hot applied bitumen @ 0.7-1.2 Kg/Sqm.
- Pea size gravel or grit @ 0.006-0.008 Cum/Sqm.
For severe climatic conditions and important structures/courses

heavy duty treatment should be given as detailed below:-
- Hot applied bitumen @ 1.464 Kg/Sqm minimum.
- Pea size gravel or grit @ 0.008 Cum/Sqm.
13.11.1.3 In the laying of 4 or 6 courses of bitumen felt, as the case may be,
over the last course of hot bitumen, stone grit or gravel of 6 mm and
down size shall be spread uniformly on horizontal surfaces. Bitumen
felts suffer from following deficiencies:
a) Contents of a factory finished felts are not viscous enough to

retain the shape and intended characteristics of roofing felt. High
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b) Defective lap joints allow seepage of water.
c) Hessian being organic in nature, it is subject to decay over the

period, resulting in decrease in tensile strength and life of tar felt.
Now a days glass fiber reinforced bitumen felts are also available in
the market which can be used in place of organic fiber or hessian
felts.
Standard application methodology:

There are certain essential pre-requisites for any bitumen based water
proofing system to be successful. These are
• The surface to be treated should be smooth, having proper slope.
• There should be no depression or cracks
• The surface should be bone dry.
• Any structural defaults in the roof or the parapet wall should be attended
to before starting the treatment.
• Detailed steps in lying of the bitumen based surface barrier systems will
be:-
i) Make surface smooth, even and dry, remove local depressions and
loose dirt.
ii) Paint the dried surface with bituminous primer and allow it to cure.
iii) Apply foundation coat of bitumen.
iv) Lay surface barrier membrane i.e. bitumen felt.
v) Apply on coat of bitumen and finish with grit or coarse sand.
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14 METAL SHEETING WORKS
14.1 GENERAL
14.1.1.1 This part of the specification covers the technical requirements of

COLOUR COATED SHEET AND ALLIED WORKS FOR ROOFING,
DECKING AND CLADDING, WITH OR WITHOUT INSULATION.
Supply and installation of the sheeting shall be done by same
agency. During handling/ stacking, if any damage is done to sheet
like distortion of edges, scratches on sheet etc., then such damaged
sheet shall stand rejected and shall be immediately replaced by the
contractor.
IS:277 - Galvanised steel sheets
IS:513 - Cold rolled carbon steel sheets
IS:901
Code Of - Practice For Use Of Cold-Formed Light Gauge Steel
Structural Members In General Building Construction
IS:1200 - Specification for Kraft paper.
IS:1397 - Steel for general structural purposes
IS:2062 Australian Code – Steel sheet and strip Hot dipped

zinc coated or aluminium-zinc coated
NZS/AS 3566:1988- Screws - Self-drilling - For the

building and construction industries
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14.3 MATERIAL
14.3.1.1 Troughed permanently colour coated metal decking sheet for

floor/roof decking shall be made by steel feed material of minimum
0.8mm bare metal thickness. Galvanised to grade 275 as per IS277,
of minimum yield strength of 250Mpa of drawing grade. Sheet shall
be colour coated with total thickness of 35 microns comprising of
silicon modified polyester SMP (with silicon content 30 -50%) paint or
super polyester paint of minimum 20microns dry film thickness (DFT)
on one side (exposed face) over 5micron primer coat and 5micron
SMP or super polyester paint over 5micron primer on other face and
of approved profile, sectional properties, colour and shade. SMP and
super polyester paint systems shall be of category 3 as per AS2728.
14.3.1.2 Troughed permanently colour coated metal sheet for roofing, side
cladding, ridges, hips, flashings, trimmings, closure for vertical &
horizontal joints,capping etc., shall be
14.3.1.3 With sheet having minimum 0.6mm (bare metal thickness) thickness
galvanised to grade 275 as per IS277, of minimum yield strength of
250Mpa of drawing grade as per IS513.
14.3.1.4 With sheet having minimum 0.5mm (bare metal thickness) thickness
coated with zinc aluminum alloy at 150gm/m2 of minimum yield
strength of 350 as per AS1397.
14.3.1.5 Steel sheet shall be colour coated as per clause 15.2.1 and shall be
of approved profile, sectional properties, colour and shade.
14.4 DESIGN REQUIREMENTS
14.4.1.1 For metal decking the sectional properties shall be calculated as per
IS801 for satisfying deflection and strength requirements. Deflection
shall be limited to span/250 under critical load combinations.
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14.4.1.2 No increase in allowable stress is permissible under wind loading

conditions.
14.4.1.3 Spacing of fastener shall be calculated based on wind load, self

weight and other associated loads and Maximum spacing of
fasteners shall be 400mm, minimum diameter of fastener shall be
5.5mm.
14.4.1.4 Sealant used for cladding shall be butyl based, two parts poly
sulphide or equivalent approved, non stainless material and be
flexible enough not to interface with fit of the sheets.
14.4.1.5 Filler blocks as a trough filler shall be used to seal cavities formed
between the profiled sheet and the support or flashing. Filler block
shall be manufacturer from black synthetic rubber or any other
material approved by ENGINEER.
14.4.1.6 Thermal insulation of sheeting panels shall be with mineral wool

conforming to IS8183. The density shall be 32kg/m3 for glass wool
and 48kg/m3 for rock wool. Minimum thickness of insulation shall be
50mm.
14.4.1.7 Special coated fasteners shall be used conforming to class 3 as per

AS3566 and shall be tested to 1000 hours salt spray test.
14.4.1.8 Percentage elongation of the mild steel sheet having minimum yield
strength of 250Mpa shall be 23% as per IS: 2062.
14.4.1.9 Tolerance on bare metal thickness of all sheeting material shall be -

0.00mm and +0.06mm.
14.5 WORKMANSHIP
14.5.1.1 The sheeting shall be fixed as per the working drawings. Sheets shall
be supplied in required sizes (based on the secondary beams ISSUE
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of sheets to lengths shall be used for cutting. Cutting and trimming of

small openings which were not finalised at the time of working
drawings can be allowed at site. Wherever possible, site cut edges
shall be concealed at laps or with flashings. Suitable steel members
for stiffening shall be provided at the cut edges. No gas cutting shall
be done on the sheet. If any sheet is found with gas cut mark, same
shall stand rejected and shall be immediately replaced.
14.5.1.2 Distorted, blemished or water stained sheets shall not be used.

Before installing decking sheet, it shall be ensured that the purlins
are in true planes, correctly placed and secured firmly.
14.5.1.3 Side and end laps of the sheets shall be made weather proof by
securing them with the fasteners not less than 4mm dis with 2mm
thick neoprene washer. Maximum spacing of the fasteners not to
exceed 500mm.
14.5.1.4 Length of the sheet shall be such as to cover minimum 3 span purlin
spacings. The roof decking sheets shall be fixed to the purlins with
the help of self drilling and tapping type fasteners and neoprene
washers.
14.5.1.5 Sheets shall be laid over the supporting purlins with a minimum
bearing of 50mm and end projection of 75mm at lap joints. End and
side laps between the sheets shall be sufficiently large to ensure the
weather tightness. In no case, the end laps shall be less than 150mm
and side laps less than one trough length with proper weather tight
arrangement.
14.5.1.6 Cladding erection for each elevation shall commence at the bottom
and proceed towards the top, in order to ensure tight fittings laps.
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14.5.1.7 In case double skin cladding, inner sheet and outer sheet can be
directly fixed to the opposite faces of the sheeting runner totally
concealing the supporting steel structure.
14.5.1.8 Flashings, cappings, trimming, closure for vertical/horizontal joints,

ridge and hips etc,. shall be provided with a minimum lap of 150mm.
The lapping of sheets shall provide the dust free, airtight enclosure. If
required this can be achieved by using 2 parts polysulphide sealing
compound or butyl tape. The black synthetic rubber external trough
fillers are to be secured by the mechanical fixings to the flashings or
parapet capping,
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15 GRILLS & RAILING WORKS
15.1 GENERAL
15.1.1 This specification covers the general requirements regarding materials and
details of fabrication and erection of Stainless Steel (SS) Handrails. The
contractor shall design, engineer, document, test, manufacture, deliver,
install, protect and commission SS Railing complete with all necessary
accessories, fixings, finishes, flashings, sealants and the like in accordance
with the Contract Documents. The scope of this Section is performance
based, and shall be developed, tested and warranted to comply with:
15.1.2 The design intentions indicated on the Drawings,
15.1.3 Specified performance criteria and requirements,
15.1.4 Relevant statutory and project requirements.
precedence.
INDIAN STANDARDS:
NBC 2005 Bureau of Indian Standards, the National Building
Code of India,
IS: 806 Code of Practice for Use of Steel Tubes in
General Building Construction.
IS: 2835 Specification for flat transparent sheet glass(third
revision)
IS: 4912 Safety Requirements for Floor and Wall Openings,
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AMERICAN STANDARDS
ASTM A554–13: Standard Specification for Welded Stainless Steel
Mechanical Tubing
ASTM E985: Standard Specification for Permanent Metal
Railing Systems and Rails for Buildings
ASTM E488: Standard Test Methods for Strength of Anchors in
Concrete and Masonry Elements
ASTM E894–88: Standard Test Method for Anchorage of Permanent
Metal Railing Systems and Rails for Buildings
ASTM E935–00: Standard Test Methods for Performance of
Permanent Metal Railing Systems and Rails for
buildings
ANSI Z97.1: Safety Glazing Materials Used in Buildings -
Safety Performance Specifications and Methods

ASTM C1172-09: Standard Specification for Laminated Architectural
Flat Glass
ASTM C1036: Standard specification for flat glass.
ASTM C1376: Standard Specification for Pyrolytic and Vacuum
Deposition Coatings on Flat Glass
BRITISH STANDARDS
CP 3012: Code of Practice for Cleaning and
Preparation of Metal Surfaces
IBC 2407: Glass in Handrails and Guards
BS EN 14179-2: Glass in building. Heat-soaked thermally-
toughened soda lime silicate safety glass
Evaluation of conformity/product standard
BS EN 1096-1: Glass in building. Coated glass Definitions
and classification
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15.3 STAINLESS STEEL HANDRAILING
15.3.1 MATERIALS
15.3.1.1 Guardrails and Handrail System
15.3.1.2 All rails and other horizontal / inclined tubular components shall be
constructed using the following:
15.3.1.3 Surface to be 320 grain/grit finish/ polish / matte/ bead blasted

Tubes 1-1/2‖ (38mm) outside diameter by 5/64‖ (2 mm) wall thickness.
All posts and other vertical components shall be constructed using the
following:
15.3.1.4 Stainless steel grade AISI type 316,
15.3.1.5 Stainless steel grade AISI, type 304,316/316L
15.3.1.6 Posts to be 2‖ (50 mm) by 1/2‖ flat bar,
15.3.1.7 Stainless steel grade AISI type 316, surface to be 320 grain/grit
finish/ polish / matte/ bead blasted for component fittings including
handrail attachment support and post attachment components Stainless
Perforated, Woven Or Welded Metal Infill Panels: As per Custom
pattern as specified herein.
15.3.1.8 Fasteners:
15.3.1.9 Anchors & Fastening bolts to be stainless steel or other high

strength material as determined by engineering requirements with
capability to sustain, without failure, load imposed within a safety factor
of 4, as determined by testing per ASTM E488.
15.3.2 QUALITY ASSURANCE
15.3.2.1 Railing Structural Requirements:

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15.3.2.2 Handrail assemblies and guards shall be designed to resist to

withstand loading of 0.74 KN/mtr UDL applied in any direction at the top
and to transfer this load through the supports to the structure.
15.3.2.3 Infill area of guardrail system shall be capable of withstanding a

horizontal concentrated load 90 Kgs to one square foot at any point in
the system. Load not to act concurrently with loads on top rail of system
in determining stress on guardrail.
15.3.2.4 Bolts, Rivets and Screws
15.3.2.5 When two stainless steel items are joined it is absolutely

necessary to use elements of stainless steel or of other materials with
an equivalent resistance to corrosion.
15.3.2.6 When stainless steel items are joined to carbon steel structural
elements the carbon steel element must be well protected by suitable
painting.
15.3.2.7 Stainless steel rivets, screws and bolts must be used and the
carbon steel element must be suitably insulated from the stainless steel
element using EPDM/ neoprene/Teflon
15.3.2.8 Welding Prior Approval To Be Obtained If Necessary:
15.3.2.9 TIG welding to be adopted for SS works. The welded areas to be

passivated after welding are completed. When welding dissimilar
ferrous metals the respective IS code to be followed.
15.3.3 WORKMANSHIP
15.3.3.1 Installation work shall not be carried out until substrates have been
properly prepared.
15.3.3.2 If substrate preparation is the responsibility of another installer;

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15.3.3.3 All works shown or inferred from the Specifications and Drawings
are intended to be the design criteria for the subcontract work. The
detailed design development shall be submitted by the Contractor for
Acceptance and Endorsement.
15.3.3.4 The Contractor shall be responsible for taking exact

measurements at site prior to fabrication and installation. He shall verify
all measurements in consultation with the Consultant.
15.3.3.5 The Contractor shall allow for any additional supports on

framework where required so as to ensure the stability and capability of
the installation to withstand all specified loads under normal usage
encountered during the service life of the works.
15.3.3.6 Field measurements: Where handrails and railings are indicated to

fit to other construction, check actual dimensions of other construction
by accurate field measurements before fabrication; show recorded
measurements on final shop drawings.
15.3.3.7 Coordinate fabrication and delivery schedule of handrails with

construction progress and sequence to avoid delay of railing
installation.
15.3.3.8 Coordinate post setting drawings, templates, instructions, and

directions for installation of anchorages, such as sleeves, concrete
inserts, anchor bolts, and miscellaneous items having integral anchors
that are to be embedded in concrete and masonry construction.
15.3.3.9 Co-ordinate delivery of anchorages to project site.
15.3.3.10 Co-ordinate that blocking is in place for all mounting fasteners.
15.3.3.11 Clean surfaces thoroughly prior to installation.
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15.3.3.12 Prepare surfaces using the methods recommended by the

manufacturer for achieving proper result for the substrate under the
project conditions.
15.3.3.13 Fabricate railing system for compliance with structural

requirements of applicable code.
15.3.3.14 Pre-assemble railings prior to shipping to greatest extent possible

to minimize field splicing and assembly. Disassemble units only as
necessary for shipping and handling limitations. Clearly mark units for
re-assembly and for coordination with shop drawings.
15.3.3.15 Stainless steel tubing cuts shall be square, without burrs and
where exposed, rounded to produce smooth rigid and hairline joints
15.3.3.16 Install in accordance with manufacturer's instructions by done a

qualified, authorized representative of the manufacturer.
15.3.3.17 Fit exposed connections accurately together to form tight joints,

except as necessary for expansion.
15.3.3.18 Perform cutting, drilling and fitting required for installation. Set
accurately in location, alignment and elevation, plumb, level and true,
measured from established lines and levels.
15.3.3.19 For in-place construction, provide anchorage devices and fittings

to secure to in-place construction; including threaded fittings for
concrete inserts, toggle bolts and through bolts. Separate dissimilar
materials with bushings, grommets or washers to prevent electrolytic
corrosion.
15.3.3.20 Do not cut or abrade finishes which cannot be completely restored

in the field. Provide anchors, plates, angles, etc., necessary for
connecting railings to structure.
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15.3.3.22 There shall be accuracy in dimensions, precision in fitting of

matching sections to line and levels, and perfection in alignment.
15.3.3.23 All components to be installed in plumb and in-line, accurately

fitted, free from distortion or defects and securely anchored to structure.

standards, and the final finish and polish shall conform true to approved
sample.
15.3.3.25 Maximum variation from plumb shall be 1/4".
15.3.3.26 Maximum offset from true alignment for every 50-foot of railing
shall be 1/4", non-accumulative.
15.3.4.1 Materials to be delivered to the job site in good condition and

adequately protected against damage as handrails are a finished
product.
15.3.4.2 Store on site in a location and manner to avoid damage. Stacking

should be done in a manner that will prevent bending. Store material in
a clean, dry location away from uncured concrete and masonry. Any
protection on the railings during transportation should remain until
installed.
15.3.4.3 Keep handling on site to a minimum. Exercise caution to avoid

damage to finishes of material.
15.3.4.4 General contractor to provide protective covering on handrails and

guardrails until handover.
15.3.4.5 Adequate protection and periodic inspection to be carried out if

construction is not yet finished in the area where the railings are
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15.3.4.6 Upon delivery railing will have protective wrapping over cap only.
Immediately upon completion of installation of railing, remove cap cover
and clean all work for inspection and approval.
15.3.4.7 When cleaning surfaces use plain water containing a mild soap or
detergent. No abrasive agents or harsh chemicals shall be used.
15.3.4.8 Touch up, repair or replace damaged products before Substantial

Completion.
15.3.4.9 All deficiencies in work and/or items not meeting specified

requirements shall be corrected in order to meet specification
requirements at no additional cost to owner.
15.3.5 WARRANTY
15.3.5.1 Finish Warranty: Manufacturer shall warranty installed system for

the periods described herein, starting from Date of Substantial
Completion. When notified in writing from Owner, manufacturer /
installer shall, promptly and without inconvenience and cost to Owner,
correct said deficiencies.
15.3.6 MEASUREMENT
15.3.6.1 Horizontal plan length of top rail only will be measured as handrail
length in Running Unit. Verticals will not be measured. Rate shall
include all labour and materials including balustrades (vertical pipes) all
necessary infill details (as shown in drawing), welding (if necessary),
tools, plants & buffing charges fixing arrangements etc complete as
directed.
15.3.6.2 Important Note:
15.3.6.3 All the specifications mentioned above are the general

standardised ones. Architectural layout plans & the detail drawings
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architectural drawings submitted should be termed as final, in case of

any discrepancies or variations, what-so-ever.
15.4 GLASS HANDRAILING
15.4.1 MATERIALS
15.4.1.1 Guardrails And Handrail System - All rails and other horizontal /
inclined tubular components shall be constructed using the following:
15.4.1.2 Stainless steel grade AISI, type 304,316/316L.Surface to be 320

grain/grit finish/ polish / matte/ bead blasted.Tubes 1-1/2‖ (38mm)
outside diameter by 5/64‖ (2 mm) wall thickness.
15.4.1.3 All posts and other vertical components shall be constructed using
the following:
15.4.1.4 Stainless steel grade AISI type 316,
15.4.1.5 Surface to be 320 grain/grit finish/ polish / matte/ bead blasted
15.4.1.6 Posts to be 2‖ (50 mm) by 1/2‖ flat bar,
15.4.1.7 Provide 1.0mm radius at all corners with ‗v-cut‘ where necessary.
15.4.1.8 All stainless steel is to be a minimum thickness of 2.0mm.
15.4.1.9 Stainless steel grade AISI type 316, surface to be 320 grain/grit
finish/ polish / matte/ bead blasted for component fittings including
handrail attachment support and post attachment components
15.4.1.10 Colour: Where indicated on the Drawings to be colour finished,

stainless steel be colour treated by an Accepted permanent process to
match Accepted colour samples. Submit details.
15.4.1.11 Provide laminated Heat Soaked Toughened Safety Glass with

polished edges and dubbed (blunt) corners complying with ASTM ISSUE
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C1048. Kind FT (fully tempered), condition A (un-coated). Types 1
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(transparent glass, flat), quality Q3 (glazing select), class, thickness and

manufacturing process as indicated below.
15.4.1.12 Clear glass: Class 1 clear
15.4.1.13 Tinted glass: Class 2 (tinted heat absorbing and light reducing).
Manufacturer‘s standard tint color or custom color as indicated below:
15.4.1.14 Custom pattern, art glass, etch, edges or surface, laminate or

embeds, as specified herein.
15.4.1.15 Allowable thickness 17.5mm thick (8 clear toughened +8 clear

toughened +1.5mm PVB interlayer) glass.
15.4.1.16 Glass shall be Fully Tempered and 100% Heat Soak Tested to EN
14179 part 1.
15.4.1.17 Provide approved opacifying films of polythene or polyester to

restrict vision where required / as specified. Film to match project
architect‘s approved sample. Film shall be fully bonded to glass with
solvent based adhesive. Provide safety backing restraint for fallout
resistance. Edge deletion of pacifying films shall be provided at all
insulating glass and structural glazing unless manufacturer submits test
data acceptable to the project architect indicating that edge deletion is
not required.
15.4.1.18 Opacifier coatings and films are required to be suitable for the
proposed temperature and exposure conditions and are required to
function without bubbling, blistering or colour shift for the design life of
the Building.
15.4.1.19 Opacifier coatings are to be applied to surface 2 of monolithic or

surface 4 of insulating glass units and prevent ―read-through‖ of the
glass.
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15.4.1.20 Anchors & Fastening bolts to be stainless steel or other high

strength material as determined by engineering requirements with
capability to sustain, without failure, load imposed within a safety factor
of 4, as determined by testing per ASTM E488.
15.4.1.21 Glass Panels:
15.4.1.22 Glass for laminating is to be cut into individual panels prior to the
laminating process.
15.4.1.23 Glass thickness of successive panes being laminated together is

not to exceed a difference of 2mm.
15.4.1.24 Heat treated glass is to be orientated so that warp, bow and roller
wave between successive panels are matched. Two stage convection
tempering ovens are to be used to ensure glass distortions are
minimized. Edge clamping of glass is forbidden.
15.4.1.25 Handrail assemblies and guards shall be designed to resist to

withstand loading of 0.74 KN/mtr UDL applied in any direction at the top
and to transfer this load through the supports to the structure.
15.4.1.26 Infill area of guardrail system shall be capable of withstanding a

horizontal concentrated load 90 Kgs to one square foot at any point in
the system. Load not to act concurrently with loads on top rail of system
in determining stress on guardrail.
15.4.1.27 When two stainless steel items are joined it is absolutely

necessary to use elements of stainless steel or of other materials with
an equivalent resistance to corrosion.
15.4.1.28 When stainless steel items are joined to carbon steel structural
elements the carbon steel element must be well protected by suitable
painting. Stainless steel rivets, screws and bolts must be used and the
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carbon steel element must be suitably insulated from the stainless steel
element using EPDM/ neoprene/Teflon
15.4.1.29 TIG welding to be adopted for SS works. The welded areas to be

passivated after welding are completed. When welding dissimilar
ferrous metals the respective IS code to be followed. Any and all field
welding shall be by a certified welder.
15.4.1.30 All laminated glass shall have clean cut edges, or polished edges
if required to eliminate thermal stress breakage risk. Laminated glass
units shall be fabricated with autoclaved edges on all four sides.
15.4.1.31 Edges of laminated glass are to be protected to prevent

delamination, contamination or other defects, caused by moisture,
sealant contact or other external/internal source.
15.4.1.32 All exposed laminated glass edges shall be protected from

blushing by hot rolling the interlayer back into the glass edge, or by use
of an approved edge seal material.
15.4.1.33 Install in accordance with manufacturer's instructions by done a

qualified, authorized representative of the manufacturer.
15.4.1.34 Fit exposed connections accurately together to form tight joints,

except as necessary for expansion.
15.4.1.35 Perform cutting, drilling and fitting required for installation. Set
accurately in location, alignment and elevation, plumb, level and true,
measured from established lines and levels.
15.4.1.36 For in-place construction, provide anchorage devices and fittings

to secure to in-place construction; including threaded fittings for
concrete inserts, toggle bolts and through bolts. Separate dissimilar
materials with bushings, grommets or washers to prevent electrolytic
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15.4.1.37 Do not cut or abrade finishes which cannot be completely restored

in the field.
15.4.1.38 Provide anchors, plates, angles, etc., necessary for connecting

railings to structure.
15.4.1.39 There shall be accuracy in dimensions, precision in fitting of

matching sections to line and levels, and perfection in alignment.
15.4.1.40 All components to be installed in plumb and in-line, accurately

fitted, free from distortion or defects and securely anchored to structure.
Maximum variation from plumb shall be 1/4".

standards, and the final finish and polish shall conform true to approved
sample.
15.4.1.42 Maximum offset from true alignment for every 50-foot of railing
shall be 1/4", non-accumulative.
15.4.1.43 Dimensional tolerances of glass generally shall comply with ASTM

C1036 Table 2.
15.4.1.44 Do not cut, work, or permanently mark after toughening. Use

installation methods which prevent the glass making direct contact with
metals or other non-resilient materials.
15.4.2 QUALITY ASSURANCE
15.4.2.1 Quality Plan - Prepare, submit and implement a detailed project

specific Quality Plan prior to execution. Products shall be reputable
proprietary products, factory manufactured under ISO 9001. Submit
quality assurance documentation for all bought-in products, including
ISO 9001 certification, and evidence of satisfactory long term
performance (at least 5 years) in similar commercial conditions.
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15.4.2.2 Quality Control Representative - Appoint a Quality Assurance

representative responsible for all quality aspects of the work of this
Section. Submit name and details.
15.4.2.3 Quality Control Procedures - Submit certifications that the

materials comply with specification required and are suitable for
intended application.
15.4.3 WORKMANSHIP
15.4.3.1 Do not begin installation until substrates have been properly

prepared.
15.4.3.2 If substrate preparation is the responsibility of another installer;

notify Architect of unsatisfactory preparation before proceeding.
15.4.3.3 All works shown or inferred from the Specifications and Drawings
are intended to be the design criteria for the subcontract work. The
detailed design development shall be submitted by the Contractor for
Acceptance and Endorsement.
15.4.3.4 The Contractor shall be responsible for taking exact

measurements at site prior to fabrication and installation. He shall verify
all measurements in consultation with the Consultant.
15.4.3.5 The Contractor shall allow for any additional supports on

framework where required so as to ensure the stability and capability of
the installation to withstand all specified loads under normal usage
encountered during the service life of the works.
15.4.3.6 Field measurements: Where handrails and railings are indicated to

fit to other construction, check actual dimensions of other construction
by accurate field measurements before fabrication; show recorded
measurements on final shop drawings.
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15.4.3.7 Coordinate fabrication and delivery schedule of handrails with

construction progress and sequence to avoid delay of railing
installation.
15.4.3.8 Coordinate post setting drawings, templates, instructions, and

directions for installation of anchorages, such as sleeves, concrete
inserts, anchor bolts, and miscellaneous items having integral anchors
that are to be embedded in concrete and masonry construction.
15.4.3.9 Co-ordinate delivery of anchorages with project site.
15.4.3.10 Co-ordinate that blocking is in place for all mounting fasteners.
15.4.3.11 Clean surfaces thoroughly prior to installation.
15.4.3.12 Prepare surfaces using the methods recommended by the

manufacturer for achieving proper result for the substrate under the
project conditions.
15.4.3.13 Fabricate railing system for compliance with structural

requirements of applicable code.
15.4.3.14 Pre-assemble railings prior to shipping to greatest extent possible

to minimize field splicing and assembly. Disassemble units only as
necessary for shipping and handling limitations. Clearly mark units for
re-assembly and for coordination with shop drawings.
15.4.3.15 Stainless steel tubing cuts shall be square, without burrs and
where exposed, rounded to produce smooth rigid and hairline joints
15.4.4 Shop Drawing & Method Statement Submissions
15.4.4.1 Submit (within the One month of the award of contract) the
Comprehensive, detailed and dimensioned shop drawings to indicate all
set-out and construction/ installation details to include and not limited to
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plans, elevations, sections, details of components, anchor details and

attachment to adjoining units of work.
15.4.4.2 Time required for examination of shop drawings will be 5 working

days for each submission, including re-submissions. The Contractor
shall incorporate required changes due to inaccurate data or incomplete
definition so that delivery and installation schedules are not affected.
The Contractor‘s revision response time is not justification for delivery
or installation delay of the subcontract works. Any re-submission shall
include requested corrections and shall be responded to previous
comments in point-by-point format.
15.4.4.3 Manufacture should not commence until Acceptance and

Endorsement has been obtained to use the relevant shop drawings.
15.4.5 Installation Procedures Manual
15.4.5.1 Submit a comprehensive manual containing all installation

procedures, equipment and personnel required for acceptance prior to
the commencement of installation works for review and Acceptance.
15.4.6 Operation and Maintenance Manuals
15.4.6.1 The O&M Manual shall include, without limitation,

recommendations for operating, and routine cleaning and maintenance,
and all information required to ensure the full service capability of the
work, including source of replacement components, and methods of
replacement of damaged components. The method of cleaning and
timetable shall be specified together with cleaning agents which can
and cannot be used.
15.4.6.2 The Operation and Maintenance Manual is to include the following

documents:
15.4.6.3 Comprehensive list of all materials suppliers and agents. ISSUE

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15.4.6.4 Finishes information – coating system type colour, supplier.
15.4.6.5 Defective works log to be kept up to date for the duration of the
warranty period outlining each defect type location and corrective action
to rectify each defect.
15.4.6.6 Clearances and tolerances.
15.4.6.7 Methods of in-service glass replacement
15.4.6.8 All Warranties from suppliers and Contracting Parties.
15.4.6.9 As-built drawings (AutoCAD Files and A3 hard copy)
15.4.7 Test Reports:
15.4.7.1 Submit test reports from qualified independent testing agency.
15.4.8 Glass
15.4.8.1 Roller Wave Distortion: in the installed work shall be horizontal

unless otherwise approved in writing. The maximum roller wave shall
not exceed 0.15 mm in any 300mm length of glass.
15.4.8.2 Bow Distortion: ‗bow‘ and ‗warp‘ shall have the same meaning.
Overall bow across the shorter glass dimension (‗the gauge length‘)
shall not exceed 0.00342 times gauge length for gauge length less than
900mm, and 0.00258 times gauge length for gauge length greater than
900mm.
15.4.8.3 100% heat soak testing will be required for all glass with edge
stress exceeding 50mpA (7500 psi). Submit Heat Soak method,
temperature, and duration for review and Acceptance, prior to
commencement.
15.4.9 MOCK-UP
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15.4.9.1 Contractor shall install a full scale mock up for a length of 7.5m of
typical detailing treatment at locations to be confirmed by the Architect.
15.4.9.2 The visual mock-up for the assembly will be required to be

Accepted and Endorsed by the Architect with respect to appearance of
colour.
15.4.10.1 Materials to be delivered to the job site in good condition and

adequately protected against damage as handrails are a finished
product.
15.4.10.2 Store on site in a location and manner to avoid damage. Stacking

should be done in a manner that will prevent bending. Store material in
a clean, dry location away from uncured concrete and masonry. Any
protection on the railings during transportation should remain until
installed.
15.4.10.3 Keep handling on site to a minimum. Exercise caution to avoid

damage to finishes of material.
15.4.10.4 Adequate protection and periodic inspection to be carried out if

construction is not yet finished in the area where the railings are
installed.
15.4.10.5 Upon delivery railing will have protective wrapping over cap only.
Immediately upon completion of installation of railing, remove cap cover
and clean all work for inspection and approval.
15.4.10.6 General contractor to provide protective covering on handrails and

guardrails until handover.
15.4.10.7 When cleaning surfaces use plain water containing a mild soap or
detergent. No abrasive agents or harsh chemicals shall be used.
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15.4.10.8 Touch up, repair or replace damaged products before Substantial

Completion.
15.4.10.9 All deficiencies in work and/or items not meeting specified

requirements shall be corrected in order to meet specification
requirements at no additional cost to owner.
15.4.11 WARRANTY
15.4.11.1 Manufacturer shall warranty installed system for the periods

described herein, starting from Date of Substantial Completion. When
notified in writing from Owner, manufacturer / installer shall, promptly
and without inconvenience and cost to Owner, correct said deficiencies.
15.4.12 MEASUREMENT
15.4.12.1 The mode of measurement will be length of railing and not length
of individual pipes/bars i.e. Horizontal plan length of top rail only will be
measured as handrail length in Running Unit. Verticals will not be
measured.
15.4.12.2 Rate shall include all labour and materials including balustrades
(vertical pipes) all necessary infill details / Glass Panels (as shown in
drg), welding (if necessary), tools, plants & buffing charges fixing
arrangements etc complete as directed.
15.4.12.3 Important Note:
15.4.12.4 All the specifications mentioned above are the general

standardised ones. Architectural layout plans & the detail drawings
should be followed / referred for all the specified design & details & the
architectural drawings submitted should be termed as final, in case of
any discrepancies or variations, what-so-ever.
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15.5 M.S. GRILLS & HANDRAILING
15.5.1 MATERIALS
15.5.1.1 Mild steel tubular sections should be used for hand railing; design
should be as per drawing.
15.5.2 WORKMANSHIP
15.5.2.1 The hand railings will be fitted in staircase and other areas without
tampering the finishing material of the stair/area. The fixing will be done
as per details shown in drawing.
15.5.3 MOCK-UP
15.5.3.1 Contractor shall install a full scale mock up for a length of 7.5m of
typical detailing treatment at locations to be confirmed by the Architect.
15.5.3.2 The visual mock-up for the assembly will be required to be

accepted and endorsed by the Architect with respect to appearance of
colour.
15.5.4 MEASUREMENT
15.5.4.1 Measurement shall be in running meter correct upto two places of

decimal.
15.5.4.2 Rate shall include all labour and materials including balustrades
(vertical pipes) welding, tools, scaffoldings, buffing charges, fixing
arrangements etc complete as directed.
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16 MISCELLANEOUS
16.1 GENERAL
16.1.1 This part of the specification covers miscellaneous items such as Inserts,
bolts, cutouts, metal lath and wire fabric.
IS:412 - Expanded metal steel sheets for general purposes.
IS:4948 - Specification for welded steel wire fabric for general use.
16.3 INSERTS, BOLTS, CUTOUTS ETC.
16.3.1 WORKMANSHIP
16.3.1.1 All the miscellaneous inserts such as bolts, pipes, plate

embedments etc. either supplied FREE by the OWNER or to be
furnished by the CONTRACTOR shall be accurately installed in the
building works at the correct locations and levels, all as detailed in the
construction drawings. CONTRACTOR shall prepare and use
templates for this purpose, if so directed by the ENGINEER. In the
event, any of the inserts are improperly installed, CONTRACTOR shall
make necessary arrangements to remove and re-install at the correct
locations/levels, all as directed by the ENGINEER without any extra
cost to the OWNER.
16.3.1.2 The rate quoted by the Bidder for concrete works shall hold good
for accurately fixing the inserts at the correct levels/alignment and shall
include the cost of any temporary supports/anchors such as bars
including cutting, bending, welding, etc. as required.
16.3.1.3 Steel templates shall be used by the CONTRACTOR to locate and

very accurately position bolts, groups of bolts, inserts, embedded parts,
etc. at his cost. Such templates shall be got previously approved by the ISSUE
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is not disturbed due to vibration, movement of labourers, materials,

shuttering work, reinforcement, etc. while concreting. The
CONTRACTOR will have to suitably bend, cut or otherwise adjust the
reinforcement in concrete at the location of inserts, as directed by the
Engineer. If the Engineer so directs, the inserts will have to be welded
to reinforcement to keep these in place. The Contractor shall be
responsible for the accuracy of dimensions, levels, alignments and
centre lines of the inserts in accordance with the drawings and for
maintenance of the same until the erection of equipment/structure or
final acceptance by the Owner.
16.3.1.4 The Contractor shall ensure proper protection of all bolts, inserts,
etc. from weather by greasing or other approved means such as
applying white lead putty and wrapping them with gunny bags or
canvas or by other means as directed by the Engineer to avoid damage
due to movement of his labourers, materials, equipment, etc. No extra
claim from the Contractor on this account shall be entertained. The
Contractor shall be solely responsible for all damage caused to bolts,
inserts, etc. due to his negligence and in case damage does occur, they
shall be rectified to the satisfaction of the Engineer at the Contractor's
cost.
16.3.1.5 Cut outs, chamfers, pockets, etc. shall be left as indicated in the
drawings and no extra cost shall be payable for providing these at their
correct locations. The Contractor shall take all necessary precautions to
protect the cut outs from accidentally getting filled up or the edges
getting broken.
16.3.2 MEASUREMENT
16.3.2.1 Miscellaneous inserts, bolts supplied by the CONTRACTOR shall

be measured and paid for as per the respective items of work. Installing
the inserts in correct location is covered in cost of brickwork/stone ISSUE
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16.4 METAL LATH & WIRE FABRIC
16.4.1 MATERIALS
16.4.1.1 Welded steel wire fabric shall conform to IS:4948
16.4.1.2 Expanded metal shall conform to IS:412
16.4.1.3 Galvanised wire mesh shall be of approved quality.
16.4.2 WORKMANSHIP
16.4.2.1 The type and details of the steel material to be used for metal lath
plastering work and at the junctions of brick masonry/concrete before
wall plastering shall be as specified in the respective items of work.
16.4.2.2 For metal lath plastering work, the weight of steel material shall be
not less than 1.6 kg/sq m.
16.4.2.3 Steel material for use at the Junction of brick masonry/ concrete
shall have the mesh dimensions not greater than 50 mm.
16.4.2.4 Steel material shall be obtained in maximum lengths as

manufactured to restrict joints to the minimum. Overlap at the joints
shall be minimum 25 mm which shall be securely tied with wires of
diameter not less than 1.25 mm at spacing not more than 100 mm for
lath plastering work. Nailing to wall shall be at spacing not exceeding
200 mm. The material shall be straightened, cut and bent to shape if
required for fixing as per the details indicated in the drawings.
16.4.3 MEASUREMENT
16.4.3.1 Measurement shall be in sq.m correct to two places of decimal for

the type as specified in the respective items of work.
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TCE-M4-419-08 SHEET 1 OF 6 OF
ALUMINIUM PANEL FALSE CEILING
1.0 SCOPE
This specification covers the requirements of false ceiling using

aluminium ceiling panels.
2.0 APPLICABLE CODES
The following specifications, standards and codes, including all official

amendments/revisions and other specifications & codes referred to
therein, should be considered as a part of this specification. In all cases
the latest issue/edition/revision shall apply. In case of discrepancy
between this specification and those referred to herein below or other
specification forming a part of this bid document, this specification shall
govern.
a) IS:733 : Specification for wrought aluminium and

aluminium alloy, bars, rods and sections (for
general engineering purposes)
b) IS:737 : Specification for wrought aluminium alloys,

sheet and strip (for general engineering purposes)
c) IS:1868 : Specification for anodic coatings on aluminium
d) IS:2062 : It specifies standards for Hot Rolled Medium and

High Tensile Structural Steel
e) IS:2441 : Code of Practice for fixing ceiling coverings.
f) IS:2629 : Recommended practice for hot-dip galvanizing of

iron and steel.
g) IS:13871: : Powder coating specification
1993
(R2009)
h) CP 290 : Code of Practice for suspended ceiling and lining
of dry construction using metal fixing system for
guidance)
i) ClSCA : Ceiling Systems Handbook.
j) ASTM C : Standard for Ceiling Suspension System

636 Installations
k) ASTM E : Standard Practice for Installation of Ceiling

580 Suspension Systems for Acoustical Tile and Lay-
in Panels in Areas Subject to Earthquake Ground
Motions.
l) IBC : (International Building Code) standard for Seismic

Zone for local area.
k) IS:4082: : Recommendations on stacking and storage of ISSUE

1996 construction materials and components at site. R4
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3.0 MATERIALS
3.1. ALUMINIUM CEILING PANELS
3.1.1 Submit shop drawings for reflected ceiling plans (RCP’s), drawn to scale,
The detailed drawings shall be based on those of other services and
shall be prepared in close co-ordination with the other vendors/agencies.
The aluminium ceiling panels to be used in the false ceiling shall be
made of aluminium alloy sheets of 19000 or 31000 of IS:737 and shall be
of a make , type and brand as approved by the ENGINEER/Architect.
Panel type :
1) Perforated
2) Non Perforated – plain, Square, Rectangular and/or strips.
3) Non Perforated - patterned
4) Non Perforated - textured
5) Mesh
Panel length : As per Architects drawings

Panel Finish : colour to be as selected by architect
Carrier : V-shaped roll-formed aluminium section with hook-
shaped tabs spaced to receive panels.
Carrier Finish : Finish is factory applied black enamel.
3.1.2 Aluminium ceiling panels, supplied by the CONTRACTOR shall be free

from any visible defects that may impair appearance or serviceability.
The surface of the sheets shall present a uniform appearance and finish
and shall have smooth surface. The panels shall have square folded
neatly trimmed straight and regular edges, and shall be square at the
corners to present uniform straight line and regular joints when erected in
position.
3.1.3 The aluminium panels shall be light weight, strong, flat, dimensionally
stable, free from sag, warp, sharp edges and shall be easy to install. The
surface shall be chemically treated to provide micro-etched surface to
promote tenacious bonding of the protective and decorative paint to be
finally applied.
3.1.4 The aluminium panels supplied by the CONTRACTOR shall be made out
of aluminium sheet of appropriate thickness as per size of panels
approved by the ENGINEER/ARCHITECT to suit grid and/or design
pattern of the false ceiling. The CONTRACTOR shall get a sample of the
panel duly approved by the ENGINEER/ARCHITECT before procuring
the panels for the entire ceiling.
3.1.5 The aluminium panels shall be stored as per suppliers instructions so as

to avoid bending or twisting during their storage or handling.
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3.2. METAL FRAME WORKS
3.2.1 The metal frame work shall be made out of rugged galvanised steel
conforming to IS: 2062 or extruded anodised aluminium sections
confirming to grade 63400 WP of IS: 737 as shown on the drawings. The
shape of cross-section of the members shall be such as to facilitate
proper suspension and proper fixing of the ceiling panels. The framework
shall also be structurally sound and rigid and of make, type and brand as
approved by the ENGINEER/ARCHITECT.
3.2.2 The metal sections shall be stored as per IS:4082:1996 so as to avoid

bending or twisting during their stacking, storage and handling.
3.3. HANGERS
3.3.1 M.S. bars or flats confirming to IS: 2062 shall be used for the hangers.
Diameter or size of the hangers should be approved by the
ENGINEER/ARCHITECT to provide adequate structural strength to hold
framework on which aluminium are to be fixed.
3.3.2 M.S. bars or flats shall be stored as per IS:4082:1996 so as to avoid

bending or twisting during their stacking, storage and handling.
4.0 WORKMANSHIP
4.1 Prior to installation, the entire execution team to have a briefing by the
supervisor on safe working practices using safety gear like helmets,
safety belts etc. Safety measures with regards to erection of scaffolding ,
working at heights, using of tools & emergency evacuation procedures to
be strictly followed to avoid any accidents. TCE.M10-PCS-10 to be
followed for Safety in Design.
4.2 The CONTRACTOR shall ensure that the frame to support the ceiling is
designed for structural strength and the sizes, weight and strength of
aluminium panels to be fixed and other loads due to live load at
75kg/sqm ( where human access is intended at particular locations, with
proper cat walks), air conditioning, grills, electrical cables /wiring and
lighting fixtures, thermal insulation etc. as shown on the drawings. The
false ceiling grid work shall be carried out as per the approved drawings
and approved load considerations as directed by the
ENGINEER/ARCHITECT.
4.3 The metal framework of extruded aluminium false ceiling grid system
shall consist of aluminium main member of special T-profile of 38 mm x
38mm x 1.5 mm interlocking with each other to form frames of various
sizes as shown on the drawing. The main members shall be suspended
from the roof structures by means of steel hangers and supported at the
walls by means of extruded aluminium wall angles 25 mm x 25 mm x 1.5
mm. In case of aluminium T-grid system, the panels shall be
manufactured a little undersized so as to be accommodated in the
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4.4 In the case of grid work made out of galvanised steel, these shall be of
such profile so that panels can be snapped into the suspension runners
with ease. Wall mound or section shall be fixed all along the perimeter of
the wall, wherever necessary.
4.5 The main grid member shall be suspended with the help of steel hangers
at 1.2 m centre to centre in both the directions. The hangers shall be
fabricated from mild steel / galvanised flats of 35 mm x 6 mm size or bar
of 10 mm diameter (or as designed by the engineer for higher loads),
threaded at the lower end and anchored securely in the roof concrete
using expansion bolts or welded to inserts provided on the underside of
slabs, beams etc. In case the roof work is of AC sheeting supported on
purlins and trusses, the hangers shall be suspended from the roof steel
work. The arrangement of metal hangers shall be such that the level of
false ceiling can be adjusted during fixing of the ceiling frame work. The
hangers shall be given two coats of red oxide zinc chromate paint
primer.
4.6 The false ceiling CONTRACTOR shall co-ordinate with air–conditioning

and electrical contractors and shall provide necessary openings in the
false ceiling work for air conditioning, lighting and other fixtures.
Additional framing and hangers where required or as directed by the
ENGINEER/ARCHITECT for the above openings/fixtures shall also be
provided at no extra cost to the OWNER. Removable or hinged
type inspection or access trap doors shall be provided at locations
specified by the ENGINEER/ARCHITECT.
5.0 DELIVERY, STORAGE AND HANDLING
5.1 Deliver system components in manufacturer’s original unopened

packages, clearly labelled.
5.2 On delivery products to be checked, verified and accepted or rejected

and recorded.
5.3 Store components in fully enclosed dry space. Carefully place on skids,
to avoid damage from moisture and other construction activities. Follow
IS: 4082:1996 guidelines for stacking and storage at site.
5.4 Handle components to prevent damage to surfaces and edges, and to

prevent distortion and other physical damage.
6.0 FINISHING
6.1 It is essential that the false ceiling work should be firm and in perfect
lines and levels and free from distortion, warp, bulge and other
defects. All defective sheets and other materials shall be removed from
site immediately and replaced, and ceiling restored to original finish
to the satisfaction of the ENGINEER/ARCHITECT.
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6.2 The workmanship is expected to be of highest quality. The joints for the
frame work shall be of interlocking type so that when the cross member is
in place, it cannot be lifted out.
6.3 All aluminium ceiling panels, tees etc. shall have a natural satin anodised
finish of grade AC 10 of IS: 1868 or approved powder coated shade If
anodised, the anodised surface shall finally be sealed for life –long finish.
6.4 Align joints in adjacent courses to form uniform, straight joints parallel to
room axis in both directions, unless otherwise indicated. Install
directionally patterned or textured panels in directions indicated on
approved shop drawings. Panel-joints shall flow smoothly and in a
straight line within 1 in 1000. Intersections shall be continuous.
6.5 Fit adjoining units to form flush, tight joints. Scribe and cut units for
accurate fit at borders and around construction penetrating ceiling.
6.6 Remove protective film from panels only when space is completely clean
and free of airborne particles. Use white cotton gloves for final
installation of panels into grid system.
6.7 Clean exposed surfaces with non-solvent, non-abrasive commercial type

cleaner.
7.0 WARRANTY
7.1 Deliver system components in manufacturer’s original unopened

packages, clearly labelled.
7.2 Provide specified manufacturer’s warranty against defects in

workmanship, discoloration, or other defect considered undesirable by
the Architect or Employer.
7.3 This warranty shall remain in effect for a minimum period of five (5) years
from date of initial acceptance.
8.0 SUBMITTALS
8.1 PRODUCT DATA
Vendor to submit following
8.1.1 Manufacturers published literature of the product.
8.1.2 Submit sample along with specification for ARCHITECT/ENGINEER

approval.
8.1.3 Methodology i: e. the application process of the product installation.
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8.2 PRODUCT CERTIFICATION
Manufacturer’s certifications that products comply with specified

requirements and governing codes including product data, laboratory test
reports and research reports showing compliance with specified
standards.
8.3 SHOP DRAWINGS
8.3.1 Submit shop drawings for reflected ceiling plans (RCP’s), drawn to scale,
the detailed drawings shall be based on those of other services and shall
be prepared in close co-ordination with the other vendors/agencies.
The vendor to show the following details:
8.3.2 Reflected Ceiling Plan(s): Indicating metal ceiling layout, the grid work,
sizes of grid members, method of suspension, position of openings for
air-conditioning and lighting, access doors, other penetrations and ceiling
mounted items etc.
8.3.3 Suspension System, Carrier and Component Layout.
8.3.4 Details of system assembly and connections to building components.
8.3.5 Samples for Verification: Full-size units (or as specified below) of each
type of ceiling assembly indicated; in sets for each colour, texture, and
pattern specified, showing the full range of variations expected in these
characteristics. samples for each type specified of product to be
submitted.
9.0 MEASUREMENT
9.1 The flat plan area of false ceiling shall be measured and paid at the unit
rate less deductions, if any. Openings in false ceiling which are less than
0.2 sq.m. in area shall not be deducted for the purpose of payment.
9.2 The quoted rates shall include supply, delivery and erection of all
materials for covering the ceiling, frame work, suspenders or hangers
and their anchoring system, making openings, supporting the main
members on masonry walls, beams, levelling and painting, including
preparing of detailed false ceiling drawings. Nothing extra shall be
payable for modification accounting to 5% of area, that may be required
at site.
9.3 All the rates shall be inclusive of all the level differences as per design
and supply-installation of full system with necessary fixtures and
fasteners when made to merge with different type of ceiling. Scaffolding
is to be included in the rate and will not be paid separately.
END
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TCE.M4-419-11 SPECIFICATION FOR ANTI-TERMITE PRECONSTRUCTIONAL
SHEET 1 OF 1
CHEMICAL TREATMENT IN BUILDINGS
1.0 SCOPE
This specification covers the general requirements for Anti-termite Constructional
Measures, chemical treatment of soils for the protection of buildings from attack by
subterranean termites, chemicals to be used with their minimum rates of application
and procedure to be followed while the building is under construction.
2.0 APPLICABLE CODES AND SPECIFICATIONS
The following codes, standards and specifications are made a part of this specification.
In case of discrepancy between this specification and those referred to herein, this
specification shall govern.
The codes and standards mentioned below shall be latest as on the day of award of
contract of the works unless otherwise specified. Contractor shall be responsible to
inform to the Consultant/ Owner in case of any revisions/re-affirm/amendment in the
relevant codes and standards after the date of award of contract within 30 days of the
issue of such revision/re-affirm/amendment of the code/ standard. Consultant/ Owner
may approve use of the earlier code/ standard if the revisions do not materially affect
the statutory requirements of the project or does not impact safety practices. Any cost
impact arising out of such revisions shall be mutually agreed.
1 IS 6313 Part 1: : Code of practice for anti-termite measures in buildings:

1981 (R2015) Part 1 Constructional measures
2 IS 6313 Part 2: : Code of Practice for Anti-Termite Measures in
2013 (R2018) Buildings - Part 2: Pre-Constructional Chemical
Treatment Measures
3 IS 6313 Part 3: : Code of Practice for Anti-termite Measures in
2013 (R2018) Buildings - Part 3: Treatment for Existing Buildings
3 IS:8944-2005 : Specification for Chloropyrifos Emusifiable
Concentrates
4 IS:16131-2015 Specification for inidacloprid suspension concentrate
5 IS:4015-1998 : Guide for Handling cases of Pesticide Poisoning
3.0 GENERAL
Contractor shall furnish all tools, plants, instruments, qualified supervisory personnel,
labour, materials, any temporary works, consumables, any and everything necessary
whether such items are specifically stated herein for completion of the job in
accordance with specification requirements or not.
All work shall be done in the order of progress required by Owner's construction
programme. Contractor shall take all necessary precautions to prevent any accident in
connection with the performance of the work.
On completion of all work, Contractor shall leave the entire premises within the site of
his operation clean and free from all rubbish resulting from his operation.
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Owner reserves the right to inspect, check and direct any or all operations at any stage
of the work and to require unsatisfactory work to be remedied at Contractor's expense.
No work shall be carried out under unsuitable weather conditions viz. when raining or
when the soil is wet due to rain or sub-soil water.
Chemicals shall be brought to site of work in sealed original containers. The materials
shall be brought in, at a time, in adequate quantity to suffice for the work. The material
shall be kept in cool and locked stores. The empties shall not be removed from the
work site till the relevant item of work has been completed and permission granted by
Owner/ Engineer.
Chemicals available in concentrated forms with concentration indicated on the sealed
containers only shall be used. Chemicals shall be diluted with water in required quantity
before use, using graduated containers to achieve the desired percentage of
concentration:
Examples:
Chlorpyriphos 20% EC 250 ml is diluted to 5 litres to give 1.0% emulsion.
Imidacloprid 30.50% SC 10.5 ml is diluted to 5 litres to give 0.075% emulsion
4.0 PRE-CONSTRUCTIONAL CHEMICAL TREATMENT

4.1 ESSENTIAL REQUIREMENTS
4.1.1 Application
Hand operated pressure pump with graduated containers shall be used to ensure
uniform spraying of the chemical. Continuous check shall be kept ensuring that the
specified quantity of chemical is used for the required area during the operation. On
large projects, a power sprayer may be used to save time and labour.
4.1.2 Condition of Formation

The treated soil barrier shall be complete and continuous under the whole of the
structure to be protected. All foundations shall be fully surrounded by and in close
contact with the barrier of treated soil. Each part of the area treated shall receive the
specified dosage of chemical.
4.1.3 Time of Application

Soil treatment shall start when the foundation trenches and pits are ready to receive
mass concrete in foundations. Laying of mass concrete shall start when the chemical
emulsion has been absorbed by the soil and the surface is quite dry. Treatment shall
not be carried out when it is raining, or soil is wet with rain or sub-soil water. The
foregoing also applies in the case of treatment to the filled earth surface within the
plinth before laying the subgrade for the floor.
4.1.4 Disturbance
The treated soil barriers shall not be disturbed after they are formed. If by chance,
treated soil barriers are disturbed, immediate steps shall be taken to restore the
continuity and completeness of the barrier system.
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4.2 Chemicals, Method and Rate of Application
4.2.1 Mound Treatment

Termite mounds within the plinth and contingent apron area shall be destroyed by
means of insecticides in the form of water suspension or emulsion which shall be
poured into the mounds at several places after breaking open the earthen structure
and making holes with crow bars. For a mound volume of about one (1) cum., four (4)
litres of an emulsion in water of one of the following shall be used:
1.0 % Chloropyrifos 20EC
0.075% Imidacloprid 30.5% EC
4.2.2 Soil Treatment

Any one of the following chemicals (conforming to Indian Standards) in water emulsion
shall be applied uniformly over the area to be treated. The treated area shall be
immediately covered by polythene sheet. It can be uncovered 2 hours before concrete
casting.
Chemical Concentration by Weight

Chloropyrifos 20 EC 1%
Imidacloprid 30.50% SC 0.075%
4.2.3 Treatment of Column-pits, Wall-trenches and Basement excavations

a) The bottom surface and the sides (up to a height of about 300 mm) of the
excavations made for column pits, wall trenches and basements shall be treated
with the chemical at the rate of 5 litres per sqm of the surface area.
b) After the column foundations and the retaining walls of the basement come up, the
backfill in immediate contact with the foundation structure shall be treated at the
rate of 7.5 litres per sqm of the vertical surface of the sub-structure for each side.
If water is used for ramming the earthfill, the chemical treatment shall be carried
out after the ramming operation is done by rodding the earth at 150 mm centres
close to the wall surface and spraying the chemical with the above dose. The earth
shall be returned in layers and the treatment shall be carried out in similar stages.
The chemical emulsion shall be directed towards the concrete or masonry
surfaces of the columns and walls so that the earth in contact with these surfaces
is well treated with the chemical.
c) In the case of R.C.C. framed structures with columns and plinth beams and R.C.C.
basements, with concrete mix 1:2:4 or richer, the treatment shall start at the depth
of 500 mm below ground level for columns and plinth beams. From this depth the
back-fill around the columns, beams and R.C.C basement walls shall be treated
at the rate of 7.5 litres/sq.m of vertical surface. The other details of treatment shall
be as laid down in clause (b) above.
4.2.4 Treatment of Top Surface of Plinth Filling

The top surface of the filled earth within plinth beams/walls shall be treated with
chemical emulsion at the rate of 5 litres per sq.m of the surface before the sand
bed/subgrade is laid. Holes up to 50 to 70 mm deep at 150 mm centres both ways shall
be made with 12 mm dia. crow-bar on the surface to facilitate saturation of the soil with
chemical emulsion.
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4.2.5 Treatment of Junction of Wall and Floor

To achieve continuity of vertical chemical barrier to inner wall surfaces from the ground
level, small channel 30 x 30 mm shall be made at all the junctions of wall and columns
with the floor (before laying the subgrade) and rod holes made in the channel up to
ground level 150 mm apart and the chemical emulsion poured along the channel at
the rate of 7.5 litres/ sqm of the vertical wall or column surface so as to soak the soil
right to the bottom. The soil shall be tamped back into place after this operation.
4.2.6 Treatment of Soil Under Apron Along External Perimeter of Building

The top surface of the consolidated earth over which the apron is to be laid shall be
treated with chemical emulsion at the rate of 5 litres/ sqm of the surface before the
apron is laid. If consolidated earth does not allow emulsion to seep through, holes up
to 50 to 75mm deep at 150 mm centres both ways may be made with12 mm diameter
mild steel rod on the surface to facilitate saturation of the soil with the chemical
emulsion.
4.2.7 Treatment of Soil Along External Perimeter of Building

After the building is complete, holes shall be made in the soil with iron rods along the
external perimeter of the building at interval of about 150 mm and depth 300 mm and
these holes filled with chemical emulsion at the rate of 7.5 litres/metre of perimeter of
the external wall. If the earth outside the building is graded on completion of building,
this treatment shall be carried out on completion of such grading. If the filling is more
than 300 mm the external perimeter treatment shall extend to the full depth of filling up
to the original ground level so as to ensure continuity of chemical barrier.
4.2.8 Treatment for Expansion Joints

Anti-termite treatment shall be supplemented by treating through the expansion joint
after the sub-grade has been laid at the rate of 2 litres per linear meter of expansion
joint.
4.2.9 Treatment of Soil Surrounding Pipes and Conduits

When pipes and conduits enter the soil inside the area of the foundations, the soil
surrounding the points of entry shall be loosened around each such pipe or conduit for
a distance of 150 mm and to a depth of 75 mm before treatment is commenced. When
they enter the soil external to the foundations, they shall be similarly treated for a
distance of over 300 mm unless they stand clear of the walls of the building by about
75 mm.
5.0 SAFETY PRECAUTIONS
All chemicals used for anti-termite treatment are poisonous and hazardous to health.
These chemicals can have an adverse effect upon health when absorbed through the
skin, inhaled as vapours or spray mists or swallowed. Person using or handling these
chemicals should be warned of these dangers and advised that absorption through the
skin is most likely source of accident poisoning. They should be cautioned to observe
carefully the safety precautions given below.
These chemicals are usually brought to site in the form of emulsifiable concentrates.
The containers should be clearly labelled and should be stored carefully so that
children and pet cannot get at them. They shall be kept securely closed.
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Particular care shall be taken to prevent skin contact with concentrates. Prolonged
exposure to dilute emulsions shall also be avoided. Workers shall wear clean clothing
and wash thoroughly with soap and water, especially before eating and smoking. In
the event of severe contamination, clothing shall be removed at once and the skin
washed with soap and water. If chemicals splash into eyes they shall be flushed with
plenty of soap and water and immediate medical attention shall be sought.
The concentrates are oil solutions and present a fire hazard owing to the use of
petroleum solvents. Flames shall not be allowed during mixing.
Care shall be taken in the application of chemicals to see that they are not allowed to
contaminate wells or springs which serve as source of drinking water.
In case of poisoning suitable measure shall be taken for protection in accordance with
IS 4015.
6.0 MEASUREMENTS
The measurements shall be made in sq.m on the basis of plinth area of the building at
ground floor only for all operations described above. Nothing extra shall be measured.
7.0 RATE
The rate shall include the cost of all materials and labour involved in all the operations
described above including making holes and refilling and making good the same.
END
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TCE.M4-419-12
FALSE OR CAVITY FLOOR SHEET 1 of 9
1. SCOPE
1.1 This specification covers the requirements of false or cavity floor constructed
over reinforced concrete floor slabs for control rooms, computer rooms, data
centers, office areas and other similar structures
2 APPLICABLE CODES AND STANDARDS
2.1 The following specifications, standards and codes, including all official
amendments and revisions and other specifications referred to therein shall
be considered as a part of this specification. In all cases the latest
issue/edition/revision shall apply. In case of discrepancy between this
specification and those referred to herein, this specification shall govern.
2.2 CODES AND STANDARDS
CISCA Ceilings and Interior Systems Construction Association

BS:476 Fire tests on building materials and structures
(Part 6 & 7)
IS:3462 Specification For Unbacked Flexible PVC
IS:1200 Methods Of Measurement Of Building And Civil
Engineering Works
3 MATERIALS
The False or Cavity Floor System shall consist of 600mm x 600mm
modular panels supported by understructure of steel pedestals and
finished in accordance with the finishes detailed herein.
All materials used in the manufacturing and installation of False or
Cavity Floor shall be environmentally friendly, non-hazardous, low
emission, containing no CFC and low impact. Panels and
understructure system shall contain a minimum of 40% recycled
content.
FILE NAME: TCE.M4-419-12

third party owing no obligation of confidentiality to Tata Consulting Engineers Limited. All information given under this version over rides all and any kind of offers, assumptions, deliverables and contracts
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FILE NAME: TCE.M4-419-12.docx TCE FORM NO. 329 R7

TCE.M4-419-12
3.1 PEDESTALS
3.1.1 The false floor shall consist of a framework of suitable structural member
designed to carry the loads specified. This frame work shall be supported on
suitably designed pedestals placed at 600 mm centre to centre in both
directions.
3.1.2 The pedestals shall consist of a steel base plate of size

100mmX100mmX3mm, a metal stud made of MS tube of minimum wall
thickness 2mm and 25mm outer diameter having adjustable lock nut and
coupling at the centre and another mild steel plate of size
75mmX75mmX3.5mm at top serving as a prop head. The above framework
shall be suitably designed to accommodate minimum 32 mm thick, 600 mm
square panels.
3.1.3 The base plate shall be fixed to the reinforced concrete floor with an approved
adhesive compound or with 4 nos. 6 mm dia. anchor fasteners. Bedding of 1:2
or richer cement sand mortar shall be provided locally under the base plates of
pedestals to provide a level surface.
3.1.4 The prop head shall be provided with mild steel lugs welded on top and each
placed perpendicular to the other for proper positioning and supporting the
main and cross members.
3.1.5 The pedestals shall be capable of height adjustment upto 50mm to

accommodate concrete floor level irregularities up to plus or minus 15 mm.
The framing members shall be completely removable and shall remain in
position without screwing or bolting to the prop heads.
3.1.6 All steel framework including steel pedestals shall be hot dip galvanized.
3.2 FLOOR PANELS
3.2.1 Steel Cementitious Core Panels:
3.2.1.1 Floor panels shall be welded construction made out of high-grade cold rolled
steel sheets top and bottom plates, joined with 100 spot welding. The
thickness of top sheet shall be minimum 0.6mm and bottom sheet shall be
minimum 0.7mm.
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3.2.1.2 The sides of the panels shall be coated with epoxy powder coating of
minimum DFT 60 microns. Hollow core of the panel shall be filled with light
weight, fire retardant, non-combustible cementitious compound to support not
less than 90% of the top surface area of the panel. The core material must
contain recycled content. The panel core shall be filled with zero void to
eliminate weak spots.
3.2.1.3 Top surface of the panel shall be finished with any of the finishing materials
with anti-static properties such as high pressure laminate (HPL), PVC sheet,
carpet or hard surface such as natural stone or ceramic tiles. The floor finishes
shall conform to the requirements of relevant IS codes.
3.2.1.4 All edges of the panels shall be covered with PVC edge trim 5mm wide and of
colour matching with the floor finish. The edge trim shall be mechanically
locked and sealed in place to avoid detachment.
3.2.1.5 The panel size may be modified suitably near electrical panels/equipments
and also to suit room dimensions, however, the panel size shall not be more
than 600mm and less than 150mm (near wall edge) unless specified
otherwise.
3.2.1.6 In case the bigger and/or non-standard panel size needs to be provided due to
services requirement, same shall be clearly mentioned in the drawing and
designed accordingly.
3.2.2 Calcium Sulphate Core Panels:
3.2.2.1 The floor panels shall be made of calcium sulphate core of minimum thickness
30mm and having high density natural Gypsum. The core shall be
manufactured by compressing multiple layers of gypsum for homogenous
density across the panel and low moisture absorption.
3.2.2.2 The top surface of the core shall be bonded and laminated with anti-static high
pressure laminate (HPL) or static dissipative/conductive vinyl sheet. Bottom
surface of the core shall be bonded with aluminum of galvanized steel sheet.
3.2.2.3 The panel edges shall be provided with total encapsulation of PVC/ABS edge
band for entire panel depth.
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3.2.3 Wood Core Panel:
3.2.3.1 The floor panel shall consist of high density chipboard / particle board core
strengthened with high performance thermosetting resin and encapsulated on
all sides including edges with corrosion resistant galvanized steel sheet. The
panel thickness shall be 35-40mm.
3.2.3.2 The particle board shall be fire resistant, termite resistant, moisture proof
quality and shall generally conform to the requirements of IS:3087 –
Specification for wood particle boards (medium density) for general purposes.
3.2.3.3 The top surface of the particle board panel shall be factory laminated with anti-
static/ESD high pressure laminate (HPL) or anti-static/ conductive / dissipative
vinyl sheet ensuring maximum bonding to steel surface. The panel edges shall
be protected with conductive PVC edge band on all sides.
3.2.4 Aluminum Panels:
3.2.4.1 The panel shall comprise of a high strength di-casting aluminum structure. The
floor panel shall be formed / machined to the size, shape and squareness
within the tolerance range as specified.
3.2.4.2 The panel surface shall be coated with epoxy coating / anodizing / nickel-
chromium coating or bare metal finish.
3.2.4.3 The floor panel shall be capable of receiving the floor finishes such as carpet,
high pressure laminate (HPL), vinyl sheet or any other hard surface such as
natural stone or ceramic tile.
3.2.4.4 Perforated panels shall be designed with no underside obstructions to

facilitate maximum air flow with minimum disturbance.
3.3 ACCESSORIES
3.3.1 Manufacturer’s listed access floor outlet boxes shall be provided in locations
as detailed on the contract drawings. Large capacity 11 ¼ inch (285.75 mm)
square service outlet boxes shall be capable of accommodating four duplex
receptacles, six individual voice/data termination points and one grommet port.
Standard capacity 7-5/16 (185.67 mm) by 6-15/16 (176.02 mm) inch service
outlet boxes shall be capable of accommodating two duplex receptacles, two
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individual voice data/termination points and one grommet port. The service
outlet box shall be a drop-in design having a hinged lid with carpet insert and
frame with tapered edge. Service outlet box shall be capable of withstanding
without failure an 800 lb. (3.55 Kn).
3.3.2 Steps, ramps, fascia plate, perimeter support, and grommets shall be as per
manufacturer's standards and shall be provided where indicated on the
contract drawings.
4 WORKMANSHIP
4.1 BASE SURFACE
4.1.1 Structural sub floor for shall be examined for unevenness, irregularities and
dampness that would affect the quality and execution of the work. Installation
work shall not be carried out until structural floor surfaces are level, clean, and
dry as completed by others.
4.1.2 Concrete sealers, if used, shall be identified and proven to be compatible with
pedestal adhesive. If other than manufacturer’s recommended adhesives or
sealers are used, verify that adhesive achieves bond to slab before
commencing work.
4.1.3 Verify dimensions on contract drawings, including level of interfaces including

abutting floor, ledges and doorsills.
4.2 INSTALLATION
4.2.1 Pedestal locations shall be established from approved shop drawings so that
mechanical and electrical work can be installed without interfering with
pedestal installation.
4.2.2 In case of expansion joint in the sub floor, expansion joint shall be provided in
the false floor. The flooring shall be separated at expansion joint and separate
pedestals and floor panels shall be provided on either side of the expansion
joint with suitable joint cover.
4.2.3 Installation of access floor shall be coordinated with other trades to maintain
the integrity of the installed system. Traffic shall not be permitted on any floor
area for 24 hours to allow the pedestal adhesive to set.
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4.2.4 Floor system and accessories shall be installed under the supervision of the
manufacturer’s authorized representative and according to manufacturer’s
recommendations.
4.2.5 No dust or debris producing operations by other trades shall be allowed in

areas where access floor is being installed to ensure proper bonding of
pedestals to sub floor.
4.2.6 Partially complete floors shall be braced against shifting to maintain the
integrity of the installed system where required.
4.2.7 Additional pedestals as needed shall support panels where floor is disrupted
by columns, walls, and cut-outs.
4.2.8 Under structure shall be aligned such that all uncut panels are
interchangeable and fit snugly but do not bind when placed in alternate
positions.
4.2.9 Fabrication tolerances shall be as mentioned in the table below:
Table 1:
Description Tolerance / Limit
Panel size ± 0.25mm
Panel Squareness ± 0.25mm - ± 0.38mm
Panel Flatness ±0.50mm - ± 0.75mm
Installed False Floor Level 1.5 mm in 3.0m or 2.5 mm overall
Height Variation between adjoining
± 0.50mm
panels
5 PERFORMANCE
5.1 LOADING
5.1.1 The floor system shall meet or exceed the specific performance requirements
under loading conditions as mentioned in the below table:
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Table 2:
Load Type Loadin value
Concentrated Load over 25mm x
350 – 1500 Kg
25mm area
Uniformly Distributed Load (UDL) 900 – 1650 Kg/m²
Rolling Load 360 Kg for 10 passes
50 kg from 1.0m height above floor
Impact Load
over 50mm dia surface
Axial Load 22.5 KN for individual pedestal
5.2 FIRE AND ELECTRICAL RESISTIVITY & CONDUCTIVITY
5.2.1 The panels shall conform to class 0 and class 1 fire ratings tested as per BS
476 (Part 6 & 7).
5.2.2 The surface and bulk electrostatic resistance shall fall in the range of 2.5x104 -
1x10² Ohms (Conductive range), 1x106 - 1x109 Ohms (Static Dissipative range)
and 1x109 – 2x1010 Ohms (Anti-static range).
5.3 HUMIDITY RESISTANCE
5.3.1 Humidity resistance for the entire system including hardware and accessories
shall be up to 100%.
6 STORAGE, HANDLING AND DELIVERY
6.1 Material received at site shall be with original packing, labels, batch dates. It
shall be untouched/ intact till issued for use of site.
6.2 Material shall be stored at properly covered dry location and shall be safe from
any sort of physical damage.
6.3 Cartons must always be stored with designated side upwards.
7 SUBMITTALS AND TESTING
7.1 Vendor shall prepare and submit a layout drawing for false floor giving all
details including supporting system for approval. If so called for, vendor shall
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TCE.M4-419-12
also submit his calculations for the supporting system with all relevant data
assumed, to the ENGINEER for his approval. Work shall be carried out on
approved drawings only.
7.2 In addition to these vendor shall submit Test reports, by an independent

testing laboratory, certifying that component parts perform as specified,
Manufacturer’s installation instructions and guidelines, Manufacturer’s Owner
Manual outlining recommended care and maintenance procedures.
8 MOCK-UPS
8.1 The contractor shall prepare and install mock-up samples as per approved
shop drawings.
8.2 Mock-up samples shall be of full size and shall be true representation of actual
works to be carried out at site. Mock-ups may be part of completed work if
undisturbed.
8.3 In case of expansion joint in the floor, the mock-up shall contain expansion
joint with necessary joint cover.
9 MEASUREMENTS
9.1 Mode of measurement will be in sqm. The Mode of measurement will be same
as flooring as mentioned in IS-1200. The superficial area of false floor shall be
measured and paid for at the quoted unit rate.
9.2 The quoted rate shall include supply, delivery at site, preparation of surface,
Ramps/steps ,cutting for supply/return Air Grills etc and for Grommet of
required size, wastages, lead & lift, grouting the system with anchor fastener,
removing all debris from the premises etc. complete, as directed and for
providing subfloor insulation (only in air conditioned areas ) with adhesives to
the entire area of existing (Below false flooring) as per manufacturer's
specifications labour, Overheads and Profits, transport, all taxes if applicable.
Rate shall also include to produce a test certificate for the specified load of
approved laboratory.
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TCE.M4-419-12
10 GUARANTEE
10.1 Contractor shall provide one (1) year guarantee, in format approved by
Owner/Engineer, against any defects caused by faulty materials and or
workmanship or non-compliance with this specification.
10.2 The installed false or cavity flooring system shall be capable of withstanding
the day to day operating load and conditions of the general office and/or
equipment room environment. The acceptable overall design life shall be 25
years.
END
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TATA CONSULTING ENGINEERS LIMITED SECTION: TITLE
TCE. M4-419-14
SPECIFICATIONS FOR FIRE PROOF DOOR SHEET 1 OF 9
1. SCOPE
1.1. This specification covers the design, supply of materials, manufacture and
installation of factory made type fire rated steel doors with 2 (two) Hours fire
rating of approved make with rating as per the requirements with all
accessories, hard wares, iron mongery, fastening materials and including
installation of door with hard wares in position.
1.2. All metal work shall be free from defects, impairing strength, durability and
appearance and shall be of the best quality for purposes specified made with
structural properties to withstand safety strains, stresses to which they shall
normally be subjected to. All Hard ware fittings and Accessories shall be of
high quality and as specified and as approved by the Engineer-In-Charge.
1.3. The Contractor shall furnish all materials, labour, operations, equipment, tools
and plant, scaffolding and incidentals necessary and required for the
completion of metal work in connection with steel doors, as called for in the
drawings, specifications and bill of quantities which cover the major
requirements only. Anything called for in the tender documents shall be
considered as applicable to the items of work concerned. The supply and
installation of additional fastenings (Metal expansion Shields), accessory
features and other items not specifically mentioned, but which are necessary
to make a complete functioning installation shall form a part of this contract.
1.4. The Contractor shall strictly follow, at all stages of work, the stipulations
contained in the Indian Standard Safety Code and the provisions of the safety
code and the provision of the safety rules as specified in the General
Conditions of the Contract for ensuring safety of men and materials.
1.5. Any approval, instructions, permission, checking, review, etc. whatsoever by
the Engineer-In-Charge, shall not relieve the Contractor of his responsibility
and obligation regarding adequacy, correctness, completeness, Safety,
strength, quality, workmanship, etc. The Contractor shall submit the Shop
drawing for all works including all details, and after check by his own
Engineer. They shall not commence the work before obtaining prior and final
approval for shop drawings incorporating the changes, if any, instructed by
Engineer-In-Charge. Such prior approval shall not relieve the Contractor from
his responsibility of correctness of design, workmanship and material errors
and omissions, if any.
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TCE. M4-419-14
2. APPLICABLE CODES & STANDARDS
2.1. All standards, specifications, acts, and codes of practice referred to herein
shall be the latest editions including all applicable official amendments and
revisions.
2.2. List of certain important Indian Standards, Acts and Codes applicable to this
work is given below. However, the applicable standards and codes shall be as
per this but not limited to the list given below:
IS : 277 Galvanized steel sheet (plain and
corrugated) of GPL Grade Z 120
coating.
IS: 3614 Part 1 and 2/ BS 476 Metallic and non-metallic fire check
Part 20 and 22 doors -Resistance test and
Performance criteria.
BS 7352 /BS EN 1935 Specification of Hinges
NBC 2016
2.3. The Fire Doors shall be Underwriters Laboratories (UL) listed/ Factory mutual
(FM) approved/ CBRI Roorkee /BIS accredited body or approved by any other
National or International standardization Bureau /Organization accredited test
laboratory.
3. MATERIALS
3.1. Following materials as per available size with the manufacturer and as
approved by the consultant should be used -
3.2. All materials, items, hardware etc. shall be subjected to approval by
Engineer-In-Charge. Necessary documentation/ test certificates shall be
furnished by the Contractor for such approval. Fire doors shall be fabricated
only after approval of materials etc., by Engineer-In-Charge.
3.3. Each Fire door shall be provided with a small metal identification plate in
suitable location indicating Fire rating, name of the Manufacturer, date of
installation and approval of approved test house.
3.4. Each vision panel shall carry a stamp of the manufacturer unless otherwise
mentioned elsewhere; all Fire Check Doors shall be of two hours (120 Min.)
fire integrity.
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TCE. M4-419-14
4. HOLLOW METAL FIRE DOOR
DOOR FRAME:
4.1. Material: Frame shall be manufactured by using Galvanized steel sheets
complying with latest IS 277. Galvanized coating shall be GPL grade Z 120
coating.
4.2. Profile: Fire Door - 2 Hour rating: Double rebate profile of size 143 x 57 mm
(+/- 0.3) with bending radius of 1.4 mm. For any variation in size, which will be
as per manufacturer’s sizes, approval to be obtained from Engineer-in charge.
4.3. Frame shall be fabricated to the thickness specified below: 16 Gauge or 1.6
mm thick.
4.3.1. Frames fabricated at factory shall be in knock down form with butt joints for
bolted assembly at site or as per manufacturer’s Specification.
4.3.2. Frames shall be provided with 3 mm thick back plates on all jambs with
provision for anchor bolt fixing to wall openings.
4.3.3. Frames shall be provided with hinge plates 3 mm thick pre-drilled to receive
approved type and make of hinges for screw mounted fixing.
4.3.4. Frames shall have factory finish-pre-punched cut outs to receive specified type
and make of hardware and iron Mongery. All cut outs including hinge plates,
strike plates to have mortar guard covers from inside to prevent cement, dust
ingress into cut outs at the time of grouting of the frame.
4.3.5. Frames shall have reinforcement pads for fixing of door closer, locks and
handles at appropriate location as per manufacturer’s details.
4.3.6. Frames shall have plug-in type rubber silencer not less than 2 mm dia on the
strike jambs for single shutter frames and on the head jambs for double
shutter frames.
4.4. The total door assembly shall ensure fire and smoke integrity as per the fire
rating.
DOOR SHUTTER:
4.5. Material: Shutter shall be manufactured with double skins press formed by
using Galvanized steel sheets complying with latest IS 277. Galvanized
coating shall be GPL grade Z 120 coating.
4.6. Profile: Shutters should be press formed with double skins in such a way to
get 46 mm thick double skin hollow door with lock seam joints at stile edges.
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TCE. M4-419-14
4.7. Fire Door shutter profile shall be as given below: Fire Door - 2 Hour rating: 18
Gauge or 1.25 mm thick.
4.7.1. Shutters shall have no visible screws or fasteners on both face and internal
reinforcement shall be provided at top, bottom and stile edges for desired fire
rating.
4.7.2. In Fill Material: Shutters shall be provided with honeycomb paper core as infill
material and to be bounded to the inner faces of the shutter or as per
Manufacturer’s specification. Door should have been tested with Infill material
proposed by the manufacturer and the same should have been approved by
CBRI.
4.7.3. Preparation: Shutters shall be provided with factory prepared and with pre-
punched cut-outs and reinforcement pads to receive the approved type and
make of Hardware and Iron Mongery. The shutter should have an interlocking
arrangement at this stile edges for flat surface on either side.
4.7.4. Shutters shall have pre-drilled hinge plates with hinge guard covers.
4.7.5. Shutters with locks shall have concealed lock box with lock fixing brackets with
pre-tapped holes and screws.
4.7.6. Shutter shall have reinforcement pad at appropriate location to receive the
locks, Door closer, Panic Bar, etc as per the approved type and make of
Hardware and all as per manufacturer’s design and conforming to Standards.
4.7.7. Necessary provision / fixing arrangements shall be provided in the shutter as
well as in the frame to receive / fix the Electromagnetic latch, Electromagnetic
contact for hooters with reinforcement pads and in such a way to connect the
same to the card access control system / IBMS. Fixing Details of the above
latches shall be provided in coordination with IBMS agency.
4.7.8. Vision panel shall be of 120 minutes fire rated (conforming to BS 476 part 22),
6mm thick borosilicate or other special substrate clear, non-wired, toughened
float glass of approved manufacturer. The Glass shall be compliant to Class A
Category of Impact Resistance to BS 6206:1981 Safety Glazing Material.
Glass shall be fixed with necessary beading. The integrity should be tested for
required fire rating.
FINISH – FRAME AND SHUTTER:
4.8. Surface of the frame and shutter shall be cleaned suitably and thoroughly
with solvents as per manufacturer’s specification.
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4.9. Zinc etch primer coating shall be applied as shop coat to receive additional
coat of primer and top coats.
4.10. Stove zinc phosphate primer (35 microns DFT) shall be applied as additional
coat.
4.11. The surface shall be neatly finished with thermo setting polyurethane paint
(35 microns DFT) of approved colour and make.
5. PACKING
5.1. Individual frames members and individual shutters shall be wrapped and
protected with self-adhesive Peel-off Polythene sheets or Co extruded PE film
to a minimum thickness of 60 Microns, with low tack adhesive and with
abrasion resistant for a minimum period of 6 months and UV resistant
capability.
5.2. Individual frames members and individual shutters shall be packed in an
individual card board boxes and to be sealed with Identification numbers.
5.3. All frames and shutters shall be marked with identification number in such a
way install the door according to the door schedule.
6. STORAGE
6.1. Frames shall be stacked flat and shutters shall be stacked vertically on
wooden runners and suitably covered as per the manufacturer’s instructions
to prevent rust and damage.
7. INSTALLATION
FRAME:
7.1. Door frames shall be assembled adjacent to the place of installation as per
the Manufacturer’s specification. Frames are not allowed for transporting in an
assembled condition. If the manufacturer is desired to transport the frames in
an assembled condition, the frames should be designed suitably and
adequate packing to be given prior to transport in order to avoid any damage,
bending etc. during transport. If any defects found during the installation, such
frames will be summarily rejected and will not be allowed to use.
7.2. After assembly it is to be ensured that all threaded preparations / joints shall
be covered by using 15 x 10 self-adhesive sponge strips at the back of the
frame to prevent penetration of grouting mortar into screw threads. The head
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TCE. M4-419-14
correct alignment and secured using M 8 x 20 mm long plated Stainless steel

bolts together with nuts spring and flat washers. Frames shall be assembled
at site with aid of roofing bolts and the protective film shall not be removed
during installation.
7.3. Assembled frame shall be kept in position within the opening by means of
bracing. In order to correctly position the frame against finished floor level or
equalize on adjustable floor anchors where specified, suitable strength PVC
nylon shims shall be used under jambs. The frame shall be checked for
squareness, alignment, twist etc. with carpenters bevel and plumb.
7.4. A tie rod shall be fixed to the frame during installation to ensure the correct
dimensions between the frame rebates and the same may be removed after
installation.
7.5. Where fixing the frame is necessitated, the required gap between frame and
jambs shall be created to accommodate the PVC nylon shims in such a way
to maintain the uniform frame level.
7.6. The following Methodology shall be followed during the installation of the
frames:
7.6.1. Site survey shall be conducted to ensure the opening size and reveal the
correct opening size prior to installation of the frames.
7.6.2. Frame shall be placed in position, brace, level etc.
7.6.3. Positions of fixings anchors shall be marked on the wall / lintel.
7.6.4. Frame shall be removed and drilled to the wall to appropriate fastener or
anchor bolts size.
7.6.5. Rod anchor shells metal expansion bolts shall be placed and fitted into the
wall.
7.6.6. Jamb spacer bracket shall be placed and fit into back of frame profile.
7.6.7. The frame shall be repositioned back into opening and realigned.
7.6.8. The CSK HD machine screws shall be lightly tightened into shells.
7.6.9. The position of the nylon shims placed behind frame shall be checked to
ensure the uniform gap between the frame and jamb.
7.6.10. The plumb shall be checked by slowly fastening the screws, its square ness
etc. and finally ensure that the frames are not deformed while tightened.
7.6.11. After fixing the frame in position, the frame shall be pressure grouted with
cement slurry 1:3 ratio or filling the precast solid block core to the frame
profile as approved. The surface after grouting shall be neatly cleaned and to
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TCE. M4-419-14
7.6.12. The frames shall be back filled through holes provided and nylon plugs shall
be inserted after cleaning the surface. Nylon plugs shall be provided to suit the
frame finish and colour.
7.6.13. The Gaps between the frame and masonry surface shall be grouted with
cement slurry and sealed with Intumescent sealant of approved make, if called
for in the Bills of quantities.
SHUTTER:
7.7. All the hardware shall be fixed to the door shutter like hinges, flush bolts,
bolts, Mortise locks, Dead lock, handle, Push plate, Door closer, Door
stoppers, etc. with the appropriate SS screws and bolts supplied.
7.8. The shutter shall be fixed in to the installed frame and the shutter is aligned to
match the hardware cut-outs in the frame. The hinge screws shall also be
tightened.
7.9. The door jamb rebate surfaces shall be cleaned of all dust, oil etc.
7.10. Self-adhesive ‘FLAT’ seal shall be affixed on the door frame rebates, on hinge
jambs, strike jambs, head member, sill etc. and ‘FLAT’ seal in the shutter shall
also be affixed by using self-adhesive EPDM smoke seal ‘FLAT’ type
(Polyethylene cross linked foam of size 2 mm thick and 12.5 mm width) as
indicated by the manufacturer and if specifically called for in the bills of
quantities.
8. HARDWARE :
8.1. Fire proof doors of all type shall be provided with Hardware required for
complete stability and integrity of the door for the proposed fire rating and
vision panel (wherever applicable). All fire doors shall be fitted with an
automatic self-closing device of same fire rating as of the door which is
capable of closing the door from any angle and against any latch fitted to the
door. The fire door shall be capable of being opened manually, not be held
open by any means other than by an electromagnetic or electro-mechanical
device which can be activated by presence of smoke and/or the fire system,
provided that this shall not apply to fire doors opening into pressurised exit
staircases.
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TCE. M4-419-14
9. PERFORMANCE REQUIREMENTS
9.1. In case of proprietary design of the manufacturers, the doors should have
valid fire test certificate from UL/FM/VDS/CBRI ROORKEE or from any other
national or international standardization Bureau/Organization, accredited
testing laboratory.
10. EXECUTION:
10.1. Shop drawings of the doors in accordance to the prototype door profile shall
be used to obtain fire test certificate. The shop drawings shall include all
details of construction, anchoring, connections, fastenings, accessories etc.
Any suitable modification in fittings, fixtures as required for project specific
installations shall have to be incorporated in door profile and approval
obtained prior to the installation of the door.
11. TESTING
11.1. Along with all material tests the complete system along with the framing shall
be tested in accordance with the criteria of BS 476: Part 22 1987 and Report
212 (1)/FR/2003; insulation at door leaf only. The door system shall be tested
using a steel Mortise latch set with a steel knob set. The ACRYLIC sealant
and the Intumescent door strip shall be tested in accordance with BS 476:
Part 20 and AS 1530: Part 4 and AS 4072: Part1
12. GUARANTEE
12.1. The doors including all hardware (excepting door closer) shall be guaranteed
for a period of 12 months from the date of installation against any
manufacturing defect.
12.2. Guarantee period for Door Closer shall be 10 years. In case of any such
defect within the guarantee period, the defected part shall be replaced by the
Contractor.
13. MEASUREMENT
13.1. The measurement for Fire Check doors shall be in numbers of different types
of doors supplied, fixed and approved by the Engineer. Different sizes of
doors shall be counted separately.
It shall include:
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TCE. M4-419-14
13.1.1. Supply of all requisite materials, manufacturing and fixing in position with the
required standard of workmanship including supply-and-fixing of fixtures,
straps, bolts, hold-fasts, spikes, nails, screws, etc. applying contractors glue
or other jointing materials, coal tarring embedded parts, glazing and
supplying and fixing of all specified fittings painting as specified.
13.1.2. All material, labour, scaffolding, use of equipment etc. for framing, fixing and
completing the item as specified.
13.1.3. Measurement shall be in square metre for clear area over one face inclusive
of exposed frame. Portions embedded in masonry/concrete/ flooring shall not
be measured.
14. SUBMITTALS
14.1. Following documentation/ drawings shall be furnished along with the Doors
14.2. Shop drawings
14.2.1. Specification/ Manufacturer’s literature, Test certificates and other

documentation for materials and items intended to be used.
14.2.2. Certificate should indicate all clauses laid down by BIS & sustainability of
assembly and integrity for required fire rating.
14.2.3. Guarantee in prescribed format in manufacturer’s stationery.
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SPEC. NO. TATA CONSULTING ENGINEERS LIMITED SECTION: WRITEUP
TCE.M4-435-06
WATER SUPPLY, SANITARY & DRAINAGE WORKS PAGE 1 OF 54
1.0 SCOPE
1.1 This specification covers the general requirements of providing and laying
water mains and water supply piping, providing and fixing sanitary fixtures
and piping and providing and laying drainage lines.
1.2 For specifications, mode of measurements and scope of work covered under
the respective items for the work included under this contract, following
documents shall be referred to in the order of precedence as given below:
a) Description of the items and notes if any given in the Schedule of

Quantities.
b) Drawings
c) Specifications.
d) Additional / Special Conditions of Contract.
e) General Conditions of Contract.
f) Applicable Codes and Standards as specified herein with

amendments/ revisions issued till date.
In the event of any discrepancy among the documents referred above, the
document in the higher order of precedence shall prevail.
1.3 In the event of any element of specification not being available in any of the
documents mentioned above, the instructions of the Engineer-in-Charge in
writing shall be followed by the Contractor.
1.4 The Work shall be carried out in accordance with the drawings and designs
as would be issued to the Contractor by the Engineer-in-Charge duly signed
and stamped by him. The Contractor shall not take cognisance of any
drawings, designs, specifications, etc. not bearing Engineer-in-Charge's
signature and stamp. Similarly the Contractor shall not take cognisance of
instructions given by any other Authority except the instructions given by the
Engineer-in-Charge in writing.
1.5 The Work shall be executed and measured as per metric dimensions given in
the Schedule of Quantities, drawings etc.
1.6 The Contractor shall acquaint himself fully with the partial provisions for
supports that may be available in the structure and utilise them to the extent
possible. In any case the Contractor shall provide all the supports regardless
of provisions that have been already made. Nothing extra shall be payable for
situations where bed plates (for supports) are not available or are not useful.
The contents of this document are proprietary and confidential to Tata Consulting
Engineers Limited (TCE) and the disclosure of the contents to anyone outside TCE
is strictly prohibited except with the prior written consent from TCE.
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TCE.M4-435-06
1.7 The Contractor shall incorporate seismic considerations of anchoring and

isolation in the design of the systems as called for the different equipment.
1.8 Shop coats of paint that may be damaged during shipment or erection shall
be cleaned off with mineral spirits, wire brushed and spot primed over the
affected areas, then coated with paint to match the finish over the adjoining
shop painted surface.
1.9 In addition to the sectional testing carried out during the construction, the
Contractor shall test the entire installation after connections to the overhead
tanks or pumping system or mains. He shall rectify all leakage and shall
replace all defective materials in the system. Any consequential damage
done, on account of Contractors carelessness, open or burst pipes or failure
of fittings, during testing and commissioning to the building, furniture and
fixtures shall be made good by the Contractor.
2.0 SCAFFOLDING
2.1 Only steel tube scaffolding of approved design shall be used for all works.
The scaffold structure shall comply with the requirements of IS: 4014 and IS:
3696. An independent tied scaffold (double scaffold), which has two lines of
standards, shall be provided with the inner line kept at least one board clear
of the finished face with extended transoms, or hop up baskets to carry an
inside board. Diagonal braces shall not prevent the material being moved
along the scaffold run. The scaffolding shall be suitably packed at the ends to
prevent damage to the finished work.
3.0 PROTECTION
3.1 Protection against damage: Care shall be taken to avoid damage from any
cause at all stages. Packing pieces used for protection shall not disfigure or
otherwise permanently mark the Works.
3.2 Surface protection shall be afforded by careful handling and the avoidance of
the use of hooks, crowbars, or other implements that are likely to damage the
works.
3.3 During installation of piping, open end of pipe shall be protected with
temporary cover to prevent dust or other materials entering in it.
3.4 Protection during construction: Decorative surfaces shall be carefully

protected during construction by a temporary cover.
3.5 Protection of finished work: At all stages of the Contract it is essential that all
works are properly protected.
3.6 Suitable packing shall be used to ensure that scaffolding does not damage
erected stone, marble, granite or other finished works.
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TCE.M4-435-06
3.7 Any disfigurement, discolouration or imperfection whatsoever due to any

reason shall not be accepted and the Contractor shall either remedy the same
or redo the work at no extra cost. The decision of the Engineer-in-Charge as
to whether any work either in whole or in part is acceptable or not shall be
final and binding on the Contractor.
4.0 GUARANTEE
4.1 The Contractor shall guarantee and undertake to maintain and rectify the
various components of the Plumbing work installed by him for successful
performance for a period as indicated in the Datasheet-A. The Contractor
shall indemnify the Engineer-in-Charge for a similar period against any
damage to property and injury to persons on account of any defective work or
maintenance carried out by the Contractor. The format and text of the
Guarantee and the Indemnity Bond shall be given by the Engineer-in-Charge.
5.0 APPLICABLE CODES, STANDARDS AND PUBLICATIONS
5.1 All equipment, supply, erection, testing and commissioning shall comply with
the requirements of Indian Standards and code of practices given below as
amended till date. All equipment and material being supplied by the contractor
shall meet the requirements of IS, and other Codes/ Publications as given
below.
SP:6(1) Structural steel sections
IS:325 Three phase induction motors
IS:554 Dimensions for pipe threads where pressure tight joints

are required on the threads
IS:694 PVC insulated cables for working voltages up to and

including 1100 V.
IS:779 Specification for water meters (domestic type)
IS:800 Code of Practice for general construction in steel
IS:1068 Electroplated coatings of nickel plus chromium and

copper plus nickel plus chromium
IS:1172 Code of Basic requirements for water supply drainage

and sanitation
IS:1367 (Part 1) Technical supply conditions for threaded steel

fasteners: Part I Introduction and general information
IS:1367 (Part 2) Technical supply conditions for threaded steel

fasteners: Part 2 Product grade sand tolerances.
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TCE.M4-435-06
IS:1554 PVC insulated (heavy duty) electric(Part 1) cables: Part 1

For working voltages up to and including 1100 V.
IS:1554 (Part 2) PVC insulated (heavy duty) electric cables: Part 2 For
working voltages from3.3 kV up to and including 11 kV.
IS:1726 Specification for cast iron man hole covers and frames
IS:1742 Code of practice for building drainage
IS:2064 Selection, installation and maintenance of sanitary

appliances - Code of practice
IS:2065 Code of practice for water supply in buildings
IS:2104 Specification for water meter boxes(domestic type)
IS:2373 Specification for water meters (bulk type)
IS:2379 Colour code for identification of pipelines.
IS:2527 Code of practice for fixing rain water gutters and down
pipes for roof drainage
IS:2629 Recommended practice for hot dip galvanizing on iron

and steel
IS:3114 Code of practice for laying of cast iron pipes

Code of practice for ancillary structures in sewerage
IS:4111 (Part 1)
system: Part 1Manholes
IS:4127 Code of practice for laying glazed stoneware pipes
IS:4853 Recommended practice for radiographic inspection of

fusion welded butt joints in steel pipes
IS:4985 Unplasticised PVC pipes for potable water supplies –

specification.
IS:5329 Code of practice for sanitary pipe work above ground for
buildings
IS:5455 Cast iron steps for manholes
IS:6159 Recommended practice for design and fabrication of

material prior to galvanising
IS:7558 Code of practice for domestic hot water installations
IS:8321 Glossary of terms applicable to plumbing work
IS:9668 Maintenance of water supplies and fire fighting.
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IS:9842 Preformed fibrous pipe insulation
IS:9912 Coal tar based coating materials and suitable primers for
protecting iron and steel pipe lines
IS:10221 Code of practice for coating and wrapping of underground

mild steel pipelines
IS:10234 Recommendations for general pipeline welding
IS:10446 Glossary of terms relating to water supply and sanitation
IS:11149 Rubber Gaskets
IS:11790 Code of practice for preparation of butt welding ends for

pipes, valves, flanges and fittings
IS:12183 (Part 1) Code of practice for plumbing in multi-storeyed buildings:

Part 1 Water Supply
IS:12251 Code of practice for drainage of building basements
BS:5572 Code of practice for sanitary pipe work
BS:6700 Specification for design, installation, testing and

maintenance of services supplying water for domestic
use within buildings and their curtilages
BS:8301 Code of practice for building drainage
BSEN274 Sanitary tap ware, waste fittings for basins, bidets and
baths. General technical specifications
IS:458 Specification for precast concrete pipes(with and without

reinforcement)
IS:651 Salt glazed stoneware pipes and fittings

IS: 1239 (Part 1) Mild steel tubes, tubulars and other wrought steel fittings:
Part 1 Mild steel tubes
IS:1239 Mild steel tubes, tubulars and other wrought steel fittings:
IS:1536 Centrifugally cast (spun) iron pressure pipes for water,
gas and sewage
IS:1538 Cast iron fittings for pressure pipes for water, gas and
sewage
IS:1729 Sand cast iron spigot and socket soil, waste and
ventilating pipes, fitting sand accessories
IS:1879 Malleable cast iron pipe fittings
IS:1978 Line pipe
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TCE.M4-435-06
IS:1979 High test line pipe
IS:2501 Copper tubes for general engineering purposes

Dimensions for pipe threads for fastening purposes: Part
IS:2643 (Part 1)
1 Basic profile and dimensions
IS: 2643 (Part 2) Dimensions for pipe threads for fastening purposes: Part
2 Tolerances
IS:2643 (Part 3) Dimensions for pipe threads for fastening purposes: Part
3 Limits of sizes
IS:3468 Pipe nuts
IS:3589 Seamless or electrically welded steel pipes for water, gas

and sewage(168.3mm to 2032mm outside diameter)
IS:3989 Centrifugally cast (spun) iron spigot and socket soil,

waste and ventilating pipes, fittings and accessories
IS:4346 Specifications for washers for use with fittings for water
services
IS:4711 Methods for sampling steel pipes, tube sand fittings
IS:6392 Steel pipe flanges
IS:6418 Cast iron and malleable cast iron flanges for general
engineering purposes.
IS:7181 Specification for horizontally cast iron double flanged

pipes for water, gas and sewage.
IS:778 Specification for copper alloy gate, globe and check

valves for water works purposes
IS:780 Specification for sluice valves for water works purposes

(50mm to 300mmsize)
IS:1703 Specification copper alloy float valves (horizontal plunger

type) for water supply fittings.
IS:2906 Specification for sluice valves for water works purposes

(350mm to 1200 mm size)
IS:3950 Specification for surface boxes for sluice valves

Specification for swing check type reflux (non return)
IS:5312 (Part 1)
valves: Part 1Single door pattern
IS:5312 Specification for swing check type reflux (non return)
valves: Part 2 Multidoor pattern
IS:12992 Safety relief valves, spring loaded: (Part 1) Part1Design
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IS:13095 Butterfly valves for general purposes
IS:771(Part 1 to 3) Specification for glazed fire clay sanitary appliances
IS:774 Specification for flushing cistern for water closets and

urinals (other than plastic cistern)
IS:775 Specification for cast iron brackets and supports for wash
basins and sinks
IS:781 Specification for cast copper alloy screw down bib taps
and stop valves for water services
IS:1700 Specification for drinking fountains
IS:2326 Specification for automatic flushing cisterns for
IS:2548 (Part 1) Specification for plastic seats and covers for water
closets: Part 1:Thermoset seats and covers
IS: 2548(Part 2) Specification for plastic seats and covers for water
closets: Part 2:Thermoplastic seats and covers
IS:2556(Part 1) Specification for vitreous sanitary appliances (vitreous

china): Part 1:General requirements

china) Part 2:Specific requirements of washdown water
closets

china) Part 3 :Specific requirements of squatting pans

china) Part 4 :Specific requirements of wash basins
Specification for vitreous sanitary appliances (vitreous

IS:2556
china) Part 6 :Specific requirements of urinals, Section 2
(Part 6 Sec 2)
Half stall urinals

IS:2556
(Part 6 Sec 4)
Partition slabs
IS:2556
(Part 6 Sec 5)
waste fittings
IS:2556
(Part 6 Sec 6)
Water spreaders for half stall urinals
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china) Part 7 :Specific requirements of half round

channels

china) Part 8: Specific requirements of siphonic
washdown water closets.

china) Part 11:Specific requirements for shower rose
IS: 2556(Part 12) Specification for vitreous sanitary appliances (vitreous

china) Part 12:Specific requirements of floor traps
IS:2556 (Part 15) Specification for vitreous sanitary appliances (vitreous

china) Part 15:Specific requirements of universal water
closets
IS:2692 Specification for ferrule for water services
IS:2717 Glossary of terms relating to vitreous enamel ware and

ceramic metal systems
IS:2963 Specifications for copper alloy waste fittings for wash

basins and sinks
IS:3311 Specification for waste plug and its accessories for sinks
and wash basins.
IS:5961 Specification for cast iron gratings for drainage purposes.
IS:6249 Specification for flush valves and fittings for marine use
IS:6411 Specification for gel coated glass fibre reinforced

polyester resin bath tubs
IS:8931 Specification for copper alloy fancy single taps,

combination tap assembly and stop valves for water
services
IS:9758 Specification for flush valves and fitting for water closets
and urinals
6.0 QUALITY ASSURANCE AND QUALITY CONTROL
6.1 The Work shall conform to high standards of design and workmanship, shall
be structurally sound and aesthetically pleasing. Quality standards prescribed
shall form the backbone for the quality assurance and quality control system.
6.2 At the site level the Contractor shall arrange the materials, their stacking/
storage in appropriate manner to ensure the quality. Contractor shall provide
equipment and manpower to test continuously the quality of materials,
assemblies etc. as directed by the Engineer-in-Charge. The test shall be
conducted continuously and the result of tests maintained. In addition the
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Contractor shall keep appropriate tools and equipment for checking

alignments, levels, slopes and evenness of surface.
6.3 The Engineer-in-Charge shall be free to carry out tests as may be considered
necessary by him at his sole discretion, from time to time, in addition to those
specified in this document. The Contractor shall provide the samples and
labour for collecting the samples. Nothing extra shall be payable to the
Contractor for samples or for the collection of the samples.
6.4 The test shall be conducted at the site laboratory that may be established by
Engineer-in-Charge or at any other Standard Laboratory selected by
Engineer-in-Charge.
6.5 The Contractor shall transport the samples to the laboratory for which nothing
extra shall be payable. In the event of Contractor failing to arrange
transportation of the samples in proper time Engineer-in-Charge shall have
them transported and recover two times the actual cost from the Contractor's
bills.
6.6 Testing charges shall be borne by the Contractor.
6.7 Testing may be witnessed by the Contractor or his authorised representative.

Whether witnessed by the Contractor or not, the test results shall be binding
on the Contractor.
7.0 SANITARY AND OTHER APPLIANCES
7.1 SCOPE OF WORK
7.1.1 Without restricting to the generality of the foregoing, sanitary and other
appliances shall inter-alia include the following:-
a) Sanitary appliances and fixtures for toilets
b) Chromium plated brass fittings
c) Stainless steel sinks
d) Accessories e.g. towel rods, toilet paper holders, soap dish,

liquid soap dispensers, towel rails, coat hooks etc.
e) Mirrors, hand driers, drinking water fountains, etc.
7.1.2 Whether specifically mentioned or not the Contractor shall provide for all
appliances and fixtures all fixing devices, nuts, washers, teflon tape, sealant,
cement, brackets, supports, paints, connectors, cp riser pipes, adopters,
bolts, screws, hangers etc as required.
7.1.3 All exposed pipes within toilets and near appliances/ fixtures shall be of
chromium plated brass or copper unless otherwise specified.
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7.2.1 All materials shall be new and of quality conforming to specifications and
subject to the approval of the Engineer-in-Charge. Wherever particular makes
are mentioned, the choice of selection shall remain with the Engineer-in-
Charge.
7.2.2 All appliances, fixtures and fittings shall be provided with all such accessories
as are required to complete the item in working condition whether specifically
mentioned or not in the Schedule of Quantities, specifications, and drawings.
Accessories shall include proper fixing arrangement, brackets, nuts, bolts,
washers, screws and required connection pieces.
7.2.3 Fixing screws shall be half round head chromium plated (CP) brass screws,
with CP brass washers unless otherwise specified.
7.2.4 Porcelain sanitary ware shall be glazed vitreous china of first quality free from
warps, cracks and glazing defects conforming to IS: 2556. The choice of the
colour of the Sanitary ware shall be that of the Engineer-in-Charge and
nothing extra shall be payable to the Contractor for fixing of Sanitary ware of
any colour.
7.2.5 Sinks for kitchen shall be of stainless steel or as specified in the Schedule of
Quantities.
7.2.6 Chromium plated fittings shall be cast brass chromium plated of the best
quality approved by the Engineer-in-Charge.
7.2.7 If supply of sanitary appliances, fixtures & fittings are in client’s scope, no
damages shall occur to the same during shifting, transportation, installation till
successful handing over. If any damage occurs, the same shall be replaced
by the contractor at his own cost.
7.2.8 All appliances, fittings and fixtures shall be fixed in a neat workmanlike
manner true to level and to heights shown on the drawings and in accordance
with the manufacturer recommendations. Care shall be taken to fix all inlet
and outlet pipes at correct positions. Faulty locations shall be made good and
any damage to the finished floor, tiling, plaster, paint, insulation or terrace
shall be made good by the Contractor at his own cost.
7.2.9 All materials shall be rust proofed; materials in direct or indirect contact shall
be compatible to prevent electrolytic or chemical (bimetallic) corrosion.
7.2.10 Sanitary appliances, subject to the type of appliance and specific

requirements, shall be fixed in accordance with the relevant standards and
the following:
a) Contractor shall, during the entire period of installation and afterwards

protect the appliances by providing suitable cover or any other
protection in order to absolutely prevent any damage to the appliances
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until satisfactory handing over. (The original protective wrapping shall

be left in position for as long as possible).
b) The appliance shall be placed in correct position or marked out in
order that pipe work can be fixed or partially fixed first.
c) The appliance shall be fixed in a manner such that it will facilitate
subsequent removal if necessary.
d) All appliances shall be securely fixed. Manufacturers' brackets and
fixing methods shall be used wherever possible. Compatible rust
proofed fixings shall be used. Fixing shall be done in a manner that
minimises noise transmission.
e) Appliances shall not be bedded (e.g. WC pans, pedestal units) in thick
strong mortar that could crack the unit (e.g. a ceramic unit).
f) Pipe connections shall be made with de-mountable unions. Pipe work
shall not be fixed in a manner that it supports or partially supports an
appliance.
g) Appliances shall be fixed so that water falls to the outlet (e.g. baths).
h) All appliances shall be secured as per the recommendations of
manufacturer.
i) Appliances shall be fixed true to level firmly fixed to anchor or
supports provided by the manufacturer and additional anchors or
supports where necessary.
7.2.11 Sizes of Sanitary fixtures given in the Specifications or in the Schedule of

Quantities are for identification with reference to the catalogues of makes
considered. Dimensions of similar models of other makes may vary within +/-
10% and the same shall be provided and no claim for extra payment shall be
entertained nor shall any payment be deducted on this account.
7.3 SQUATTING TYPE WATER CLOSET - ORISSA PATTERN
7.3.1 Squatting type water closet (WC) pan shall be of Orissa pattern of size as
specified in Schedule of Quantities. Each WC pan shall be provided with a
100mm dia cast iron or porcelain P or S trap with or without vent horn as
directed by the Engineer-in-Charge.
7.3.2 WC shall be flushed by means of concealed type or exposed type (as detailed
in the drawings or as directed by the Engineer-in-Charge) 32mm size CP
brass flush valve with regulator valve or cistern.
7.3.3 WC shall be fixed securely with trap by rich cement mortar & supported
properly with brickwork.
7.4 WASH DOWN WATER CLOSET
7.4.1 WC shall be wash down or siphonic wash down type floor or wall mounted
set, as shown in the drawings, designed for low volume flushing from 3-6
litres of water, flushed by means of a flushing cistern or an exposed or
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concealed type (as detailed in the drawings or as directed by the Engineer-in-

Charge) 32mm size CP brass flush valve with regulator valve. Flush pipe/
bend shall be connected to the WC by means of a suitable rubber adaptor.
Wall hung WC shall be supported by CI floor mounted chair which shall be
fixed in a manner as approved by the Engineer-in-Charge.
7.4.2 Each WC set shall be provided with a solid plastic seat, rubber buffers and
chromium plated brass hinges. Plastic seat shall be so fixed that it remains
absolutely stationary in vertical position without falling down on the WC.
7.4.3 Each WC set shall be provided with a fixed type CP brass ablution jet, if
called for in schedule of quantities, complete with CP/ plastic piping,
concealed type CP brass angle cock etc. all of approved make and brand.
The nozzle of the ablution jet and its holding down plate shall have smooth
and rounded edges and shall not be capable of causing any injury to a user or
cleaner.
7.5 UNIVERSAL TYPE WATER CLOSET
7.5.1 Universal type water closet shall be wash down or siphonic type floor
mounted porcelain ware flushed by means of a porcelain flushing cistern or
an exposed or concealed type (as detailed in the drawings or as directed by
the Engineer-in-Charge) 32mm size CP brass flush valve with regulator valve.
Flush pipe/ bend shall be connected to the WC by means of a suitable rubber
adaptor.
7.5.2 Each WC set shall be provided with a solid plastic seat, rubber buffers and
chromium plated brass hinges. Plastic seat shall be so fixed that it remains
absolutely stationary in vertical position without falling down on the WC.
7.5.3 Clause 7.4.3 shall apply.
7.6 URINALS
7.6.1 Urinals shall be lipped type half stall white glazed vitreous china of size as
called for in the Schedule of Quantities.
7.6.2 Half stall urinals shall be provided with 15mm dia CP spreader, 32mm dia CP
domical waste and CP cast brass bottle/”P” trap with pipe and wall flange and
shall be fixed to wall by CI brackets, CI wall clips and CP brass screws as
recommended by manufacturer complete as directed by the Engineer-in-
Charge.
7.6.3 Flushing for urinals shall be by means of no hand operation, PVC or ceramic
flushing cistern / electronic auto flush valve with all internal fittings, mounted
on a C.I. brackets, and painted with two coats of approved paint of approved
shade and confirming to IS: 2326.
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7.6.4 Flush pipes shall be PVC pipes concealed in wall chase but with chromium
plated bends at inlet and outlet or as given in Schedule of Quantities. These
shall be measured and paid for separately.
7.6.5 PVC waste pipes shall be provided for urinals. Waste pipes may be exposed
on wall or concealed in chase as directed by the Engineer-in-Charge. These
shall be measured and paid for separately.
7.7 URINAL PARTITIONS
7.7.1 Urinal partitions shall be white glazed vitreous china of size specified in the
7.7.2 Porcelain partitions shall be fixed at proper heights with CP brass bolts,
anchor fasteners and MS clips as recommended by the manufacturer and
7.8 WASH BASIN
7.8.1 Wash basins shall be white glazed vitreous china of size, shape and type
specified in the Schedule of Quantities.
7.8.2 Each basin shall be provided with painted MS angle or C.I. brackets and clips
and the basin securely fixed to wall. Placing of basins over the brackets
without secure fixing shall not be accepted. The MS angle shall be provided
with two coats of red oxide primer and two coats of synthetic enamel paint of
make, brand and colour as approved by the Engineer-in-Charge.
7.8.3 Each basin shall be provided with 32mm dia CP waste with overflow, pop-up
waste or rubber plug, CP angle valve, CP riser pipe with connectors /
adoptors and CP brass chain as specified in the Schedule of Quantities,
32mm dia CP brass bottle trap with CP pipe to wall flange.
7.8.4 Wash basin shall be provided with hot and cold water mixing fitting or as
specified in the Schedule of Quantities.
7.8.5 Basins shall be fixed at proper heights as shown on drawings. If height is not
specified, the rim level shall be 790mm from finished floor level or as directed
by the Engineer-in-Charge.
7.9 SINKS
7.9.1 Sinks shall be stainless steel or any other material as specified in the
7.9.2 Each sink shall be provided with painted MS or CI brackets and clips and
securely fixed. Counter top sinks shall be fixed with suitable painted angle
iron brackets or clips as recommended by the manufacturer. Each sink shall
be provided with 40mm dia CP waste, CP angle valve, CP riser pipe with
connectors / adoptors and rubber plug with CP brass chain as given in the
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Schedule of Quantities. The MS angle shall be provided with two coats of red
oxide primer and two coats of synthetic enamel paint of make, brand and
colour as approved by the Engineer-in-Charge.
7.9.3 Supply fittings for sinks shall be deck mounted CP swivel faucets with or
without hot and cold water mixing fittings as specified in the Schedule of
Quantities. These shall be measured and paid for separately.
7.10 MIRRORS
7.10.1 Mirrors shall be electro coated, 6.0 mm thick glass of approved make, plane
or bevelled edge. The size shall be as specified in the Schedule of Quantities
or as shown on the drawings. The image shall be clear and without waviness
at all angles of vision.
7.10.2 Mirrors shall be provided with backing of 12mm thick marine plywood, fixed
with CP brass semi-round headed screws and cup washers or CP brass
clamps as specified or instructed by Engineer-in-Charge.
7.11 SHOWER SET
7.11.1 Shower set shall comprise of two CP brass concealed stop cocks, four/ five
way auto-diverter, adjustable type overhead shower, all with CP wall flanges
of approved quality all as specified in the Schedule of Quantities. Bath spout,
shower head / rose, hand showers and pop up wastes shall also be provided
wherever specified.
7.11.2 Wall flange shall be kept clear off the finished wall. Wall flanges embedded in
the finishing shall not be accepted.
7.12 TOILET PAPER HOLDER
7.12.1 Toilet paper holder shall be white glazed vitreous china of size, shape and
type specified in the Schedule of Quantities or of stainless steel/powder
coated brass.
7.12.2 Porcelain toilet paper holder shall be fixed in walls and set in cement mortar
1:2 (1 cement: 2coarse sand) and fixed in relation to the tiling work.
7.12.3 The latter shall be fixed by means of crews/capping having finish similar to
the toilet paper holder in wall/ timber partitions with rawl plugs or nylon
sleeves. When fixed on timber partition, it shall be fixed on a solid wooden
base ember provided by the Engineer-in-Charge through another agency.
7.13 TOWEL RAIL
7.13.1 Towel rail shall be chromium plated brass or of stainless steel or powder
coated brass of size, shape and type specified in the Schedule of Quantities.
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7.13.2 Towel rail shall be fixed with screws/capping having finish similar to the towel
rail in wall with rawl plugs or nylon sleeves and shall include cutting and
making good as required or directed by the Engineer-in-Charge.
7.14 LIQUID SOAP DISPENSER
7.14.1 Liquid Soap dispenser shall be wall/ counter mounted suitable for dispensing
liquid soaps, lotions, detergents as specified in schedule of quantities.
7.14.2 Liquid soap dispenser shall be with C.P. brass bracket, caps etc. fixed to wall
with C.P. brass screws, and screwed onto wooden rawl plug. The container
shall be of C.P. brass.
7.15 DRINKING WATER FOUNTAIN
7.15.1 It shall have built-in RO filtration & UV System.
7.15.2 Drinking water fountain shall be wall mounting type made of stainless steel or
any other material as given in the Schedule of Quantities.
7.15.3 The drinking water fountain shall be with anti-squirt bubble less, self closing
valve type with automatic volume regulator.
7.15.4 The drinking water fountain shall be provided with an anti-splash back and
integral strainer with 32mm or 40mm cast brass trap.
7.16 HAND DRIER
7.16.1 The hand drier shall be no touch operating type with solid state time delay to
allow user to keep hand in any position.
7.16.2 The hand drier shall be fully hygienic, rated for continuous repeat use (CRU).
7.16.3 The rating of hand drier shall be such that time required to dry a pair of hands
up to wrists is approximately 30 seconds.
7.16.4 The hand drier shall be of wall mounting type suitable for 230 V, single phase,
50 Hz, ac power supply.
7.16.5 The material of construction, size and finishing shall be as specified in

7.17 MEASUREMENT AND RATES
7.17.1 Sanitary fixtures (Porcelain ware and CP fittings) shall be measured by

numbers.
7.17.2 Rate for providing and fixing of sanitary fixtures, accessories, shall include all
items, and operations stated in the respective specifications and Schedule of
Quantities and nothing extra is payable.
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7.17.3 Rates for all items under specification Clauses above shall be inclusive of
cutting holes and chases and making good the same, CP brass screws, nuts,
bolts and any other fixing arrangements required and recommended by
manufacturers, testing and commissioning etc. complete.
8.0 SOIL, WASTE, VENT AND RAINWATER PIPES
8.1 SCOPE OF WORK
Soil, waste, vent and rain water disposal scope shall includes Supply,
Installation, testing, commissioning and successful handing over to client as
per the drawings, specifications and schedule of quantities.
All soil, waste and storm water disposal for the portion above ground level to
the public sewers shall be by gravity, whereas from the basements it shall be
by pumping. Without restricting to the generality of the foregoing, the soil,
waste, vent and rain water pipes system shall inter-alia include the following:
a) Vertical and horizontal soil, waste, vent and rainwater pipes and
fittings, joints, supports, paints and connections to fixtures.
b) Connection of all pipes to sewer lines as shown on the drawings at

ground level.
c) Floor and urinal traps, clean out plugs, inlet fittings and rainwater
(roof) outlets.
d) Testing of all pipes and fittings in the workshop.
e) Testing, commissioning and handing over of all pipes lines after

installation.
8.2.1 Pipes and fittings shall be fixed truly vertical, horizontal or in slopes as
required in a neat workmanlike manner.
8.2.2 Pipes shall be fixed in a manner so as to provide easy accessibility for repair
and maintenance and shall not cause obstruction in shafts, passages etc.
8.2.3 Pipes shall be securely fixed to walls, and ceilings by suitable clamps at
intervals specified. Only approved type of anchor fasteners shall be used for
fixing pipes on RCC ceilings and RCC/ masonry walls.
8.2.4 Access doors for fittings and clean outs shall be so located that they are
easily accessible for repair and maintenance.
8.2.5 Long bends shall be used on all main pipelines as far as possible. Use of
elbows shall be restricted for short connections.
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8.2.6 Wherever piping is going across the separation/expansion joints of buildings,

piping shall be provided with flexible connectors on both sides of such joints
or on single side depending on whether any wall is to be crossed or not.
8.3 CAST IRON PIPES AND FITTINGS
8.3.1 Soil, waste, vent and anti-siphon pipes, fittings and accessories shall be cast
iron pipes. All pipes shall be straight and smooth and their inside free from
irregular bore, blow holes, crack sand other manufacturing defects. Pipes
shall be centrifugally cast (spun) iron soil pipes conforming to IS: 3989 or
sand cast to IS: 1729.
8.3.2 Drip seal PJS-43 shall be used for jointing CI pipes & fittings as per
manufacturer’s specifications.
8.3.3 Fittings
a) Fittings shall conform to the same Indian Standard as for pipes.

Contractor shall use pipes and fittings of matching specifications.
b) Fittings shall be of the required degree of curvature with or without

access door as detailed in the drawings or as directed.
c) Access door shall be made up with 3mm thick insertion rubber washer
and white lead. The bolts shall be lubricated with grease or white lead
for easy removal later. The fixing shall be air and water tight.
8.3.4 Fixing
a) All vertical pipes shall be fixed by GI clamps truly vertical. Branch pipes
shall be connected to the stack at the same angle as that of the fittings.
No collars shall be used on vertical stacks. Each stack shall be terminated
at top with a cowl (terminal guard).
b) Horizontal pipes running along ceiling shall be fixed on structural

adjustable clamps of special design shown on the drawings or as directed.
Horizontal pipes shall be laid to uniform slope and the clamps adjusted to
the proper levels so that the pipes fully rest on them.
c) Contractor shall provide all sleeves, openings, hangers, inserts during the
construction. He shall provide all necessary information to the building
Contractor for making such provisions in the structure as necessary. All
damages shall be made good by the Contractor at his own cost to restore
the surfaces.
d) GI Pipe sleeve one size higher than pipe diameter shall be provided in
wall / floor, wherever pipe crossing wall / floor. Annular space between
pipe and sleeve shall be filled with glass wool and approved sealant as
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per manufacturer’s recommendations. Fire sealants shall be provided,

wherever pipes crossing fire rated zone.
8.3.5 Clamps
a) Holder bat clamps shall be of standard design fabricated from GI flats

40x3mm thick and 10 to 12mm dia GI rod and 6 to 10mm GI nuts and
bolts; clamps shall be painted with two coats of synthetic enamel paint
over one coat of zinc primer before fixing. The clamps shall be fixed in
cement concrete 1:2:4 mix (1 cement : 2 sand : 4 stone aggregate
20mm nominal size) blocks 100x100x100mm deep.
b) Where holder bat clamps are to be fixed in RCC column or slotted

angles, walls or beam they shall be fixed with 40x3mm flat iron "U"
type clamps with anchor fasteners of approved design.
c) Structural clamps shall be fabricated from GI structural members e.g.

rods, angles, channels, flats as per detailed drawing or as directed.
Contractor shall provide all nuts, bolts, welding material and paint the
clamps with one coat of zinc primer and two or more coats of synthetic
enamel paint to give an even shade.
d) Slotted angle/ channel supports on walls shall be provided wherever

shown on drawings. Angles/channels/ bolts shall be of sizes shown on
drawings or specified in Schedule of Quantities. Angles/channels shall
be fixed to brick walls with bolts embedded in cement concrete blocks
of 1:2:4 mix (1 cement : 2 sand : 4 stone aggregate 20mm nominal
size) and to RCC walls with suitable anchor fasteners as directed by
the Engineer-in-Charge. The spacing of support bolts horizontally shall
not exceed 1m.
e) Wherever GI clamps are required to be anchored directly to brick

walls, concrete slabs, beams or columns, nothing extra shall be
payable for clamping arrangement, RCC block and making good with
cement concrete 1:2:4 mix (1 cement : 2 sand : 4stone aggregate
20mm nominal size) as directed by the Engineer-in-Charge.
8.3.6 Traps
a) Cast iron "P" siphon traps
Cast iron "P" siphon traps shall be cast iron trap of self cleaning
design. The trap and waste pipes shall be set in cement concrete
blocks of size 300mm x 300mm and of required depth, firmly
supported on the structural floor. The blocks shall be in 1:2:4 mix (1
cement:2 coarse sand : 4 stone aggregate 20mm nominal size) and
extended to 40mm below finished floor level. Contractor shall provide
all necessary shuttering and centering for the blocks at no extra cost.
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b) Urinal traps
Urinal traps shall be cast iron P or S traps with or without vent and set
in cement concrete block specified under clause 8.3.6 a)
c) Floor trap inlet
Floor trap shall be C.I. floor trap as per IS: 3989. Bath room traps and
connections shall ensure free and silent flow of discharging water.
Where specified, Contractor shall provide a special type cast iron/GI
inlet hopper without or with one or two or three inlet sockets to receive
the waste pipe. Joint between waste and hopper inlet socket shall be
lead caulked. Hopper shall be connected to a CI P or S trap with at
least 50mm seal (hopper and traps shall be paid for separately). Floor
trap inlet hoppers and the traps shall be set in cement concrete blocks
as specified under clause 8.3.6 above without extra charge.
8.3.7 CI PIPE JOINTING
Soil, waste, vent, anti-siphonand & rain water pipes shall be jointed with
dripseal PJS-43. Sufficient skein of jute rope shall be caulked to leave a
minimum space for the drip seal to be applied in.
The following minimum procedures shall be complied with while making the
pipe joints:
a) Ensure that the pipes are clean internally and undamaged.

b) The pipes shall be cut square with sharp tools.
c) The cut ends of the pipes shall be filed/ reamed and finished smooth.
d) Any deformed ends shall be re-rounded.
e) It shall be ensured that the pipe ends shall enter the fittings and
sockets to full depth of the jointing area.
f) The pipe work shall be assembled in a manner such that it does not
entail making of joints in restricted locations.
g) Each metal pipe spigot shall be centered with three lightly wedged
pieces of hardwood or folded lead.
h) The jointing surfaces shall be cleaned to remove any coatings or
cutting oils, etc.
8.4 CAST IRON LA PIPEWORK FOR DRAINAGE
8.4.1 All drainage lines passing under building, floors, in exposed position above
ground e.g. basement ceiling shall be Cast Iron LA pipes. Position of such
pipes shall generally be shown on the drawings.
8.4.2 Cast Iron LA pipes & fittings shall conforming to IS: 1536 & IS: 1538
respectively. Quality certificates shall be furnished.
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8.4.3 Wherever possible junction from branch pipes shall be made by a “Y” tee.
8.4.4 Clean out plugs shall be provided on head of each drain and at location
indicated on plans or directed by the Engineer-in-Charge. Clean out plugs
shall be of size matching the full bore of the pipe. Plugs shall be made out
with GI coupling caulked into the socket of the pipe or fittings. The end shall
be provided with a brass screwed plug with suitable key for opening.
8.5 CAST IRON & CAST IRON LA PIPEWORK INSTALLATION
8.5.1 Laying
a) All cast iron pipes and fittings shall be jointed with drip seal PJS-43
which shall be free from impurities. In wet trenches joints shall be
made from lead wool. Nothing extra shall be paid for lead wool joints.
Depth of dripseal and weight for joints shall be as per the relevant IS
code or recommended by manufacturer, whichever is on higher side.
b) The spigot of pipe or fittings shall be centered in the adjoining socket

by caulking. Sufficient turns of tarred gaskin shall be given to leave
unfilled the required depth of socket for depth of 45mm when the
gaskin has been caulked tightly home. Joining ring shall be placed
round the barrel and against the face of the socket. drip seal shall then
be applied to fill the remainder of the socket. This shall be done in one
pouring.
c) For lead wool joints the socket shall be caulked with tarred gaskin, as
explained above. The lead wool shall be inserted into the sockets and
tightly caulked home, skein by skein, with suitable tools and hammers
of not less than 2 kg weight until joint is filled.
d) Instead of drip seal joints, Rubber ring joints can also be provided. In
case of CI pipes of spigot-socket with rubber ring joints as specified in
BOQ, the rubber rings shall conform to IS-5382.
e) It is recommended to provide rubber ring joints.
8.5.2 Cement Concrete Encasing
a) Cast iron soil and waste pipes under floor finish in sunken slabs and in
wall chases (when cut specially for the pipe) shall be encased in
cement concrete 1:2:4 mix (1 cement :2 coarse sand :4stone
aggregate 12mm size) 75mm in bed and all around. When pipes are
running well above the structural slab, the encased pipes shall be
supported with suitable cement concrete pillars, the details of which
shall be furnished by the Engineer-in-Charge of required height at
intervals of 1.8m. Rate for concrete all around pipes shall be inclusive
of pillars, supports, shuttering and centering.
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8.5.3 Painting
a) Soil, waste, vent, anti-siphonage and rain water pipes in any exposed
location in shafts, pipe spaces etc. shall be painted with one coats of
zinc / red oxide primer and two or more coats of synthetic enamel
paint of colour as specified to give an even shade.
b) Pipes shall be painted with paint of approved quality and shade in

accordance with approved pipe colour code.
c) GI waste pipes / hoppers in chase shall be painted with two coats of

bitumen paint. Exposed pipes shall be painted with two or more coats
of synthetic enamel paint over two coats of etch primer.
d) CI soil and waste pipes below ground and those covered in cement
concrete shall not be painted.
8.5.4 Cutting and Making Good Holes/ Chases
Pipes shall be fixed and tested as the building work proceeds. Contractor
shall provide all necessary holes, cut outs and chases in structural members
as the building work proceeds. Wherever holes are cut or left originally, they
shall be made good with cement concrete 1:1:2 (1 cement: 1coarse sand :2
stone aggregate 20mm nominal size) or cement mortar 1:2 (1 cement :2
coarse sand) as directed by the Engineer-in-Charge and the surface restored
as in original condition to the entire satisfaction of the Engineer-in-Charge at
no extra cost.
8.5.5 Testing
a) Testing shall be done in accordance with IS: 1172 and IS: 5329
except as may be modified herein under.
b) Before use at site all CI pipes shall be tested by filling up with water
for at least 30 minutes. After filling, pipes shall be struck with a
hammer and inspected for blow holes and cracks. All defective pipes
shall be rejected and removed from the site within 48 hours. Pipes
with minor sweating may be accepted at the discretion of the
Engineer-in-Charge.
c) Soil and waste pipes shall be tested in sections after installation, by

filling up the stack with water. All openings and connections shall be
suitably plugged as approved by the Engineer-in-Charge. The total
head in the stack shall be 4.5m at the highest point of the section
under test. A tolerance of 2 litres/cm of diameter/ km of pipeline
measured during the last ten minutes of the period of test shall be
allowed. The period of test shall be as directed by the Engineer-in-
Charge. If any leakage is visible, the defective part of the work shall
be cut out and made good. A slight amount of sweating which is
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uniform may be allowed but excessive sweating from a particular pipe

or joint shall be watched and shall be construed to be a defect and
shall be made good.
d) The Contractor shall test all vent pipes by a smoke testing machine.
Smoke shall be pumped into the stack after plugging all inlets and
connections and filling water in all trap seals. The test shall be
conducted under a pressure of 25mm of water and shall be
maintained for 15 minutes. The stack shall then be observed for
leakages and all defective pipes and fittings removed or repaired as
e) A test register shall be maintained and all entries signed and dated by
Contractor and Engineer-in-Charge. A proforma of the proposed test
register shall be submitted to the Engineer-in-Charge for approval.
f) All pipes in wall chase or meant to be encased or buried shall be

hydro tested before the chase is plastered or the pipe encased or
buried.
8.6 UPVC PIPEWORK
UPVC SWR pipework shall be provided for above ground soil, waste, vent &
rain water pipework as shown in drawings. UPVC SWR pipes & fittings shall
confirm to IS: 13592 & IS : 14735 respectively. Pipes shall be of Type - B,
pressure rating 6kgs/cm2. The pipes shall be supplied in nominal lengths of
2,3,4 or 6 meters, tolerance on specified lengths shall be +10mm and – 0mm.
Any physical test requirements shall be as per IS13592-1992.
8.6.1 Handling
Because of their lightweight, there may be a tendency for the UPVC pipes to
be thrown often during installation. Reasonable care should be taken in
handling and storage to prevent damage to the pipes. The pipes shall be
stored as per manufacturer’s recommendation. The contractor shall be fully
responsible in this case. In no case, pipes should be dragged on the
ground. Pipes should be given adequate supports at all times.
8.6.2 Pipework Installation
UPVC pipes shall be laid under the flooring or hanging below slab or fixed on
walls either buried or exposed as the case may be, as shown in the drawings.
The minimum thickness of fittings shall be of 3.2 mm. the fittings shall be of
injection mould type with solvent cement joint (for exposed piping) or rubber
ring joint (for concealed piping). The pipes and fittings shall be capable of
withstanding sun’s rays. UPVC pipes laid below slab or suspended from
ceiling shall be supported by GI angle brackets / supports as detailed in the
drawings.
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a) All vertical pipes shall be fixed by GI clamps truly horizontal. Branch

pipes shall be connected to the stack at the same angle as that of the
fittings. No collars shall be used on vertical stacks. Each stack shall be
terminated at top with a vent cowl (terminal guard).
b) Horizontal pipes running along ceiling shall be fixed on structural

adjustable clamps of special design shown on the drawings or as
directed. Horizontal pipes shall be laid to uniform slope and the clamps
adjusted to the proper levels so that the pipes fully rest on them.
c) Contractor shall provide all sleeves, openings, hangers and anchor

fasteners during the construction. Sleeves shall be one size higher
then pipe or there should be at least 12 mm gap all around between
pipes & sleeves. Wherever pipe passes through fire rated wall, the gap
shall be filled with fire rated sealant as directed by engineer. For non-
fire rated wall, gap shall be filled with wool & silicon sealant(20 mm
depth). Contractor shall provide all necessary information to the
building work contractor for making such provisions in the structure as
necessary. All damages shall be made good by the Contractor at his
own cost to restore the surface.
d) Door type fittings shall be used in vertical piping installations. Door

position of fittings shall be on top of fitting. Access door shall be made
easily removal. The access door shall be air and water tight. Single -
yee shall be used for horizontal branch connection. Double - yee
fittings shall be used in vertical piping branch connection only.
8.6.3 Jointing
UPVC pipes & fittings shall be joined as per the manufacturer’s instructions /
recommendations. UPVC pipes and fittings shall be joined with Solvent
Cement and jointing shall be carried out as follows
a) Cut the spigot end of the pipe square.
b) All burrs from the internal and external surfaces should be removed.
c) The spigot should be marked with a pencil line at a distance equivalent

to the socket depth. Clean the surface within the marked area.
d) Apply uniform coat of approved solvent cement on the external surface

to the pipe and a lighter coat on the internal surface of the fitting.
e) Insert the pipe end into the socket of the fitting and push it in upto the
mark.
f) The pipe work should be assembled in a manner such that it does not
entail making of joints in restricted area.
8.6.4 UPVC Pipework Testing

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a) UPVC pipes and fittings assembled shall be tested in accordance with

IS 13592 - 1992. The openings of the pipes shall be sealed for the
section to be tested. The water column of 2m and shall be maintained
for a maximum of 15 minutes. Contractor with their team shall examine
carefully all the joints for leakage.
b) The Contractor shall test all vent pipes by a smoke testing machine.
Smoke shall be pumped into the stack after plugging all inlets and
connections and filling water in all trap seals. The test shall be
conducted under a pressure of 25 mm of water and shall be
maintained for 15 minutes. The stack shall then be observed for
leakages and all defective pipes and fittings removed or repaired as
c) A test register shall be maintained and all entries signed and dated by
Contractor and Engineer-in-Charge. A pro-forma of the proposed test
register shall be submitted to the Engineer-in-Charge for approval.
d) All pipes in wall chase or meant to be encased or buried shall be hydro

tested before the chase is plastered or the pipe encased or buried.
e) All systems shall be tested in sections as required to expedite the work

for other trades and meet construction schedules and final test on
completion.
8.7 WASTE PIPE FROM APPLIANCES
8.7.1 Waste pipe from appliances e.g. washbasins, baths, sinks and urinals etc.
shall be of UPVC confirming IS 4985 as given in the Schedule of Quantities.
8.7.2 The internal diameter sizes of outlet branch waste pipes for different fittings
shall be as follows :
Wash basin - 40 dia
Urinals - 50 dia
Sink - 50 dia
Nahani Trap - 75 dia, 50 mm seal
Multi Floor Trap - 75 or 100 dia. as required, with

50 mm or 75 mm seal
Wash troughs - 50 dia.
Canteen wash areas - 50 dia.
8.7.3 All pipes shall be fixed in gradient towards the outfalls of drains. Pipes inside
a toilet room shall be in chase unless otherwise shown on drawings. Where
required pipes may be run at ceiling level in suitable gradient and supported
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on structural clamps as directed by the Engineer-in-Charge. Spacing for the

clamps shall be 3000mm for vertical runs and 2400mm for horizontal runs.
8.7.4 Pipes shall be UPVC tubes conforming to IS: 4985 and quality certificates
shall be furnished. Pipes shall be provided with all required fittings conforming
to IS: 4985 e.g. tees, couplings, bends, elbows, unions, reducers, nipples,
plugs etc. All UPVC waste pipes shall be terminated at the point of connection
with the appliance with an outlet of suitable diameter. Pipes shall be painted
as specified under Clause c).
8.8 DRAINAGE ACCESSORIES
a) Floor Trap / Urinal Trap Grating
Floor/ urinal traps grating shall be of stainless steel square / round of

size 125 x 125 mm square/round as approved by client & shown in the
drawing. Floor trap assembly shall be provided with round stainless
steel strainer basket as a cockroach trap. Entire assembly shall be
complete with ring, frame, outer cup, inner cup, grating, screws etc. of
an approved make.
b) Floor Cleanout
Floor cleanout cover shall be of stainless steel square / round of size

125 x 125 mm square/round as approved by client & shown in the
drawing. Floor cleanout assembly shall be complete with ring, outer
frame, cover, screws etc. of an approved make.
c) Ceiling Cleanout
Ceiling cleanout cover shall be in nickle bronze / PVC plug type / GI

flanged type of round shape matching pipe size as approved by client
& shown in the drawing. Ceiling cleanout assembly shall be threaded
with key hole for opening / flanged type suitable for pipe. Threaded
cover shall be used upto 100 mm size & above shall be GI flanged
type with GI nuts & bolts. PVC cover shall be used for PVC drainage
piping only, whereas nickle bronze & GI flanged type cover shall be
used for HDPE / CI / CI LA pipiwork.
8.9 RAINWATER PIPES
All rainwater pipes shall be of UPVC / HDPE as shown in drawing & specified
in specification. UPVC piping shall conforming to IS: 4985 and 6 kg/sq.cm
minimum pressure rating or as specified in the schedule of quantities.
8.10 HDPE PIPEWORK
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HDPE shall be used for above ground rain water pipework as shown in
drawing & specified in specification. HDPE pipes shall confirm to IS 14333 PE
80 grade, pressure rating shall be as indicated in schedule of quantities.
8.10.1 General HDPE Material Requirements
a) The color of the pipe shall be black.
b) High density polyethylene (HDPE) material used for the manufacture

of pipes shall conform to designation PEEWA-45-T-006 of IS 7328:
1992. HDPE conforming to designation PEEWA-45-T-012 of IS 7328:
1992 may also be used with the exception that melt flow rate (MFR)
shall not exceed 1.10 g/10 min.
c) When tested from a composite sample of minimum three pipes as per

IS 2530:1963, at 190° C with nominal load of 5 kgf, Melting Flow Rate
shall be between 0.4 to 1.1 g/10 min (both inclusive) and also shall not
differ by more than 20 percent of he MFR of the material used in
manufacturing pipes declared by the manufacturer.
d) The percentage of anti-oxidant used shall not be more than 0.3

percent by mass of finished resin.
e) The outside diameter of pipes, tolerance on the same and ovality of

pipe shall be as given in table.
Nominal Outside Diameter, Tolerance, Ovality,

Diameter, mm mm mm
DN
63 63.0 0.6 1.5
75 75.0 0.7 1.6
90 90.0 0.9 1.8
110 110.0 1.0 2.2
125 125.0 1.2 2.5
140 140.0 1.3 2.8
160 160.0 1.5 3.2
180 180.0 1.7 3.6
200 200.0 1.8 4.0
225 225.0 2.1 4.5
250 250.0 2.3 5.0
280 280.0 2.6 9.8
315 315.0 2.9 11.1
355 355.0 3.2 12.5
400 400.0 3.6 14.0
450 450.0 4.1 15.6
500 500.0 4.5 17.5
560 560.0 5.0 19.6
630 630.0 5.7 22.1
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f) three pipes, in accordance with IS 2530:1963, the carbon black content

shall be within 2.5 (+-) 0.5 percent and the dispersion of carbon black
shall be satisfactory.
g) Tolerance on outside diameter and maximum ovality:
The values specified for tolerance on outside diameter have been

calculated as 0.009 DN, rounded off to the next higher 0.1 mm, subject to
minimum of 0.3 mm. No negative tolerances are allowed.
h) The pressure rating of HDPE pipes specials shall be confirming to IS:

14333 or equivalent international standard with temperature & maximum
allowable operating pressure criteria as per IS: 14333.
i) Each straight length of the pipe shall clearly be marked in inedible

ink/paint (inkjet printing) at every one meter with the following information:
i) The manufacturer’s name and /trademark
ii) Designation of the pipe as per the standard specified.
iii) Lot number/Batch number/year of mfg.
iv) The words “PROJECT NAME”.
j) All HDPE fabricated fittings shall be manufactured from the pipe itself
made out of same raw material & dimensions as specified above. Fitting
shall be strictly fabricated in factory at pipe manufacturing facility.
Necessary certificate to be provided by the manufacturer. No fabrication
or moulding will be allowed at site, unless specifically permitted by the
Engineer.
k) Manufacturer to provide drawings for HDPE fittings and non HDPE

specials.
8.10.2 HDPE Pipework Jointing
Pipes shall be joined using butt fusion joint. Manufacturer's recommendation /

instructionsshall be strictly followed during pipe jointing procedure.
8.11 RAIN WATER OUTLET
a) Rain water out shall be preferably scupper type drain with cast iron
body & cast aluminium grating with stainless steel screws. Suitable
adopter / connector shall be used to match the pipe. Wherever shafts
are not available near rain water outlet, dome type rain water outlet
shall be installed.
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b) Rain water outlet shall be tested for water leaking, prior to

waterproofing treatment. Extreme care shall be taken, while sealing
gap between raai water outlet & wall / slab.
8.12.1 General
a) Rates for all items shall be inclusive of all work and items called for in
the specifications given above and the Schedule of Quantities as
applicable for the work under floors, in shafts or at ceiling level at all
heights and depths.
b) All rates are inclusive of cutting holes and chases in RCC and
masonry work and making good the same.
c) All rates are inclusive of shop testing, pre-testing at site and final
testing of the installations, materials and commissioning.
8.12.2 Pipes
a) The unit of measurement shall be linear metre to the nearest

centimetre.
b) All CI / UPVC / HDPE soil, waste, vent, anti-siphonage and rain water
pipes shall be measured net, correct to a centimetre, including all
fittings along their length after fixing. The length shall be taken along
centre line of the pipes and fittings. No allowance shall be made for
the portions of pipe lengths entering the sockets of the adjacent pipes
or fittings. The above shall apply to all cases i.e. whether pipes are
fixed on wall face or pillars or embedded in masonry or pipes running
at ceiling level. The quoted rate shall include lead jointing.
c) All CI / UPVC / HDPE pipes shall be measured in running metre

correct to a centimetre for the finished work which shall include fittings
e.g. bends, tees, elbows, reducers, crosses, sockets, nipples, nuts,
unions etc. The length shall be taken along centre line of the pipes
and fittings. All pipes and fittings shall be classified according to their
diameter, method of jointing and fixing substance, quality and finish.
The diameters shall be nominal diameter of internal bore. In case of
fittings of unequal bore, the largest bore shall be considered.
8.12.3 Pipe Encasing/ supports
a) Cement concrete around pipes shall be measured along the centre of

the pipe line measured per linear metre and include any masonry
supports, shuttering and centering, curing, cutting etc. complete as
described in the relevant specifications.
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8.12.4 GI Supports
a) GI Supports rate for pipework shall be included in the quoted

BOQ/SOQ rate and shall include GI channels/ angles (structural steel
members), GI bolts, GI nuts, GI washers, brass screws, SS fasteners,
GI threaded rod, GI clamps, GI hangers, primer coating, painting etc.
Length of supports embedded in the cement concrete blocks of 1:2:4
(1cement: 2 coarse sand: 4 stone aggregate 20mm nominal size)
formed in the masonry walls; shall not be paid extra. Also nothing shall
be paid extra for the cement concrete block and making good the
masonry wall, anchor fasteners etc. complete.
8.12.5 Traps
a) Unit of measurement shall be the number of pieces. All urinal traps,

trap gratings, hoppers, clean out plugs shall be measured by number
and shall include all items described in the relevant specifications and
Schedule of Quantities. Cockroach traps shall not be measured
separately and are deemed to be included in the rate for Traps.
8.12.6 Painting
a) Painting of pipes shall be measured per running metre for each

diameter of pipe and shall be inclusive of all fittings and clamps. No
deduction shall be made for fittings.
8.12.7 Excavation for soil pipes
a) No extra payment shall be admissible for excavation, dewatering,

back filling, consolidation and disposal of surplus earth for soil and
waste pipes.
8.12.8 Rain Water Outlet
a) Rain water outlet shall be measured by numbers for different sizes.
b) Leaf and gravel grates along with the perforated ring shall be
measured in kgs.
9.0 WATER SUPPLY SYSTEM
9.1 SCOPE OF WORK
The scope shall include supply, installation, testing, commissioning and

satisfactory handing over of the complete water supply system to client as per
drawings, specifications and schedule of quantities. The water supply system
shall inter-alia include the following:
a) Distribution system from main supply or overhead tank to all fixtures

and appliances for cold and hot water.
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b) Insulation for hot water pipes
c) Pipe protection and painting.
d) Control valves, masonry chambers and other appurtenances.
e) Connections to all plumbing fixtures, tanks, appliances and municipal

mains
f) Inserts, nozzles for R.C.C. tanks
The term water supply is used as indicative of all water supply work required
and necessary for the building including such external work as may be
necessary to make the system functional.
9.2.4 If necessary and if approved by the Engineer-in-Charge, where unavoidable,

bends may be formed by means of a hydraulic pipe bending machine for
pipes up to 20mm dia. No bending shall be done for pipes of 25mm dia and
above. After bending zinc rich paint shall be applied wherever the zinc coating
is damaged.
9.2.5 Valves and other appurtenances shall be so located as to provide easy

accessibility for operations, maintenance and repairs. Valves shall be located
at a height not exceeding 1.6m above their operating floor/ platform level.
Where such a provision is not possible and the valve is to be frequently
operated a MS chain shall be provided for its operation.
9.3 GI PIPES, FITTINGS AND VALVES
9.3.1 All pipes inside the buildings and where specified, outside the building shall
be M.S. galvanized steel tubes conforming to IS: 1239 of Class specified.
When Class is not specified they shall be Heavy Class. All embedded /
concealed pipes shall be of heavy duty.
9.3.2 Fittings shall be of malleable cast iron galvanized, of approved make. Each
fitting shall have manufacturer's trade mark stamped on it. Fittings for GI
pipes shall include couplings, bends, tees, reducers, nipples, unions, bushes
etc. Fittings etc. shall conform to IS: 1879.
9.3.3 Pipes and fittings shall be jointed with screwed joints using Teflon tape
suitable for water pipes. Care shall be taken to remove burr from the end of
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the pipe after cutting by a round file. All pipes shall be fixed in accordance
with layout and alignment shown on the drawings. Care shall be taken to
avoid air pockets. Necessary vents and drains shall be provided at all high
and low points respectively. GI pipes inside toilets shall be fixed in wall
chases well above the floor. No pipes shall be run inside a sunken floor as far
as possible. Pipes may be run under the ceiling or floors and other areas as
shown on drawings. All pipe joints after testing of the line shall be seal welded
and the weld plus the adjoining portion shall be given two coats of zinc rich
primer.
9.3.4 Bib cocks and stop cocks
All bib cocks and stop cocks shall be of C.P. brass conforming to IS: 781 of
tested quality and approved make and design, of diameter as specified in
9.3.5 Clamps
GI pipes in shafts and other locations shall be supported by GI clamps of

design approved by the Engineer-in-Charge. Pipes in wall chases shall be
anchored by iron hooks. Pipes at ceiling level shall be supported on structural
clamps fabricated from MS structurals as described in Clause 8.3.5. Pipes in
shafts shall be supported on slotted angles/ channels as specified/ as
directed.
9.3.6 Unions
Contractor shall provide adequate number of unions on all pipes to enable

easy dismantling later when required. Unions shall be provided near each
gunmetal valve, stop cock or check valve and on straight runs as necessary
at appropriate locations as required for easy dismantling and/ or as directed
9.3.7 Flanges
Flanged connections shall be provided on pipes as required for maintenance/

ease in dismantling or where shown on the drawings, all equipment
connections as necessary and required or as directed by the Engineer-in-
Charge. Connections shall be made by the correct number and size of the GI
nuts/ bolts as per relevant IS Standards and made with 3mm thick insertion
rubber washer/gasket. Where hot water or steam connections are made
insertion gasket shall be of suitable high temperature grade and quality
approved by the Engineer-in-Charge. Bolt hole dia for flanges shall conform
to match the specification for CI sluice valve as per IS: 780. Gaskets shall
conform to IS: 11149.
9.3.8 Trenches
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All GI pipes below ground shall be laid in trenches with a minimum cover of
600mm. The width and depth of the trenches shall be as follows except at
places where welding/ jointing etc. needs larger width of trench. Additional
width/ depth shall be provided as necessary for welding/ jointing etc. at no
additional cost:
Diameter of pipe Width of trench Depth of trench
15mm to 50mm 300mm 750mm
65mm to 100mm 450mm 1000mm
9.3.9 Sand filling
GI pipes in trenches shall be protected with fine sand 150mm all around
before filling in the trenches.
9.3.10 Painting
a) All pipes above ground shall be painted with one coat of red lead and
two coats of synthetic enamel paint of approved shade and quality to
give an even shade, or as specified by the Engineer-in-Charge.
b) Hot water pipes in chase:
All hot water pipes fixed in wall chase shall be properly insulated by
elastomeric tape as per manufacturer’s recommendation.
9.3.11 Pipe protection
Where specified, pipes below floor or below ground shall be protected against
corrosion by the application of two or more coats of solvent based rubberised
asphaltic primer to give a uniform coat covered with 'Pipecoat Hiper', a
puncture resistant non woven polyester mat. The application of pipecoat
primer and "Hiper" membrane shall be as specified by the manufacturer.
9.4 DI (DUCTILE IRON) PIPES & FITTINGS
Ductile iron pipes & fittings spigot & socket type shall be used for external
buried cold water supply piping work. Ductile iron pressure pipes and fittings
shall be Class K7 unless otherwise shown on the drawings and shall comply
with IS: 8329 and IS: 9523. All fittings shall be socketed unless specified
otherwise.
9.4.1 The following standards, specifications and codes are part of this
specification. In all cases, the latest revision of the codes including all
applicable official amendments and revisions shall be referred to. In case
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discrepancy between this specification and those referred to herein, this

specification shall govern.
a) IS: 8329 Centrifugally Cast (spun) ductile Iron pressure pipes

for water, gas and sewage
b) IS: 638 Sheet rubber jointing and rubber insertion jointing
c) IS: 1387 General requirements for supply of metallurgical
materials
d) IS: 1500 Methods for Brinell hardness test for metallic
materials
e) IS: 9523 Ductile Iron fittings for pressure pipes for water, gas
and sewage
f) 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
g) IS0: 4179 Ductile iron pipes for pressure and non-pressure -
Centrifugal cement mortar lining - General
requirements
h) ISO: 2531 Ductile iron pipes, fittings and accessories for
pressure pipe lines
i) IS: 5382 Specification for Rubber Sealing Rings for Gas
Mains, Water Mains and Sewers
j) AWWA C 600 Installation of ductile iron water mains and their
appurtenances
k) IS: 3784 Excavation Work - Code of Safety
l) IS: 12288 Code of practice for use & laying of Ductile iron
pipes
m) IS: 460 Test sieves – Part I
n) ISO: 8179 For zinc coating
9.4.2 Materials
The materials used in the manufacture of pipes and fittings shall comply with
IS: 8329 and IS: 9523. All fittings shall be socketed unless otherwise
specified.
9.4.3 Manufacturing
General
a) DI pipes (Class K7) and DI fittings (Class K7) with internal Cement
Mortar lining shall be in accordance with IS 8329 and IS 9523. Pipes
shall be ISI marked.
b) Pipes and fittings shall be procured from reputed manufacturers with

Engineer’s approval. Engineer shall at all reasonable times have free
access to the place where the pipes and fittings are manufactured for
the purpose of examining and testing the pipes and fittings and for
witnessing the test and manufacturing.
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c) The pipes will be centrifugally cast (spun) Ductile Iron pipes for Water
and Sewage as per relevant ISO (amended up to date) having
specifications / properties equal to or superior to the IS 8329: 2000
(amended up to date). The pipes used will be with push on joints
(Rubber Gasket Joints).
d) The flange connection shall be used only in cases of fittings or
specials or under special circumferences as directed by Engineer. The
pipes shall be externally coated with bitumen as per appendix C of the
IS 8329: 2000 and have factory provided cement mortar lining in the
inside as per the provisions of Appendix B of the IS 8329: 2000.
e) The pipes shall be supplied in standard length of 5.50 and 6.00 meters
length with suitably rounded or chamfered ends. Each pipe of the push
on joint variety shall also be supplied with a rubber ring (EPDM/SBR)
gasket. Any change in the stipulated lengths will be approved by the
Engineer. The gaskets will confirm to the IS 5382:1985 and IS:12820.
f) The manufacturer of the pipes should also supply the specials and
gaskets. The manufacturer of the pipes should preferably manufacture
them. In case they are not, it will be the responsibility of the
manufacturer of the pipes to have them manufactured from a suitable
manufacturer under its own supervision and have it tested at his/sub
contractor’s premises as per the contract. The pipe manufacturer will
however be responsible for the compatibility and quality of the
products.
g) The flanged joints will confirm to the Clause 6.2 of IS 8329. The pipe
supply will also include one rubber gaskets for each flange.
h) All tests specified either in this specification or in the relevant Indian
Standards specified above shall be performed by the
supplier/contractor at his own cost and in presence of Engineer if
desired. For this, sufficient notice before testing of the pipes and
fittings shall be given to Engineer.
i) If the test is found unsatisfactory, Engineer may reject any or all pipes
and fittings of that lot. The decision of Engineer in this matter shall be
final and binding on the contractor and not subject to any arbitration or
appeal.
j) The pipes and fittings shall be stripped, with all precautions necessary
to avoid warping or shrinking defects. The pipes and fittings shall be
free from defects. Any defect in pipes and fittings in the opinion of
Engineer shall be rejected and shall be replaced by new one.
k) In the case of spigot and socket pipes and fittings the socket shall be
without the centering ring.
l) 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 centre line. The bolt hole
circle shall be concentric 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 pipe shall be correctly aligned.
m) All the DI fittings shall be supplied with one rubber ring for each
socket.
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9.4.4 Dimensions and Tolerances
The internal diameter, thickness and length of barrel, dimensions of pipes and
fittings shall be as per the relevant tables of IS 8329/IS 9523 for different
class of pipes and fittings. Standard length of 6m of pipe is recommended and
other properties for pipes and fittings shall be as per IS 8329 / IS 9523. Each
pipe supplied shall be of uniform thickness throughout its length. The
tolerances for pipes and fittings regarding dimensions, mass, ovality and
deviations from straight line in case of pipes shall be as per IS 8329/IS 9523.
9.4.5 Testing
Tests on pipes and fittings shall be carried out in accordance with IS 8329
and IS 9523. The Engineer shall be permitted free access to the place of
manufacture for the purpose of examining and witnessing the testing of pipes
and fittings.
9.4.6 Failure to pass the test
All pipes or joints which are proved to be in any way defective shall be
replaced or remade and re-tested as often as may be necessary until a
satisfactory test shall have been obtained. Any work which fails or is proved
by test to the unsatisfactory in any way shall be redone by the Contractor.
9.4.7 Lubrication for DI Pipework
General
This section covers the requirements for lubricant for the assembly of Ductile
Iron pipes and specials suitable for Tyton push-on rubber ring joints.
Specification
The lubricant has to have the following characteristics:
a) must have a paste like consistency and be ready for use

b) has to adhere to wet and dry surfaces of DI pipes and rubber rings
c) to be applied in hot and cold weather; ambient temperature 0 - 50°C,
temperature of exposed pipes up to 70 °C
d) must be non toxic
e) must be water soluble
f) must not affect the properties of the drinking water carried in the pipes
g) must not have an objectionable odour
h) must not be harmful to the skin
i) must have a shelf live not less than 2 years
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9.4.8 Acceptance Test
They shall be conducted in line with the provisions of the IS: 9523.
9.4.9 Joints
Jointing of DI pipes and fittings shall be done as per IS: 12288 and
manufacturer’s recommendations. After jointing, extraneous material, if any,
shall be removed from the inside of the pipe. Rubber sealing rings/gaskets
used for jointing shall conform to IS: 638, IS: 12820 and IS: 5382.
9.4.9.1 Spigot and Socket Joints
These shall have sockets which are integral with the pipe and incorporate an
elastomeric rubber ring gasket conforming to IS: 12820 and rubber rings shall
be as per IS: 5382.
In jointing DI pipes and fittings, the Contractor shall take into account the
manufacturer’s recommendations as to the methods and equipment to be
used in assembling the joints. In particular the Contractor shall ensure that
the spigot end of the pipe to be jointed is smooth and has been properly
chamfered, so that the rubber ring as per IS 12820 and IS 5382 is correctly
positioned in line, before the joint is made. The rubber rings and any
recommended lubricant shall be obtained only through the pipe supplier or as
otherwise directed by the Engineer.
9.4.9.2 Gaskets for Flanges
The gaskets used between flanges of pipes shall be of EPDM conforming to

IS 638 of thickness between 1.5 to 3 mm suitable for sewage conveyance.
9.4.9.3 Flanged Joints
These shall comply with dimensions and drilling details in IS 8329 for PN 10
flanges. All flanged joints between steel and ductile iron pipe work shall be
electrically isolated joints. These shall have isolation gaskets between the
flanges, isolation sleeves around all bolts and isolation washers under all bolt
heads and nuts. All materials shall be supplied by a specialist manufacturer
and be to the approval of the Engineer.
Each bolt should be tightened a little at a time taking care to tighten

diametrically opposite bolts alternatively. The recommended bolting torque to
be followed for assembling flanges shall be as specified in manufacturer’s
instructions. The practice of fully tightening the bolts one after another is
highly undesirable. The bolts shall be of mild steel unless otherwise specified.
They shall be coated with coal tar epoxy coating after tightening.
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9.4.10 Cement Mortar Lining
All pipes and fittings shall be internally lined with cement mortar in
accordance with ISO: 4179 / IS: 11906. Cement mortar lining shall be applied
at the factory in conformance with the above mentioned standards. No
admixtures in the mortar shall be used without the approval of the Engineer.
Pipe linings shall be inspected on site and any damage or defective areas
shall be made good to the satisfaction of the Engineer. The Contractor may
use specialist mortars, mortar additives or curing agents only with the
approval of the Engineer.
Lining shall be uniform in thickness all along the pipe. The minimum thickness
of factory applied cement mortar lining shall be 3 mm for DN 300 mm pipe; 5
mm for DN 350 to 600 mm pipe; and 6mm for DN 800 mm pipes.
Certain sections are amplified as follows:-
a) No additives shall be used without the written approval of the

Engineer, and shall be used strictly in accordance with the
manufacturer’s recommendations.
b) The minimum thickness of the lining at one point shall not be less than
4 mm.
9.4.11 Specials
Standard DI fittings (Class K7) shall be in accordance with IS: 9523.

Wherever standard DI specials are not available, they shall be manufactured
and tested as per requirements with the approval of Engineer.
9.4.12 Coatings
a) General
Ductile iron pipes and fittings shall be zinc coated with bitumen over coating,
all in accordance with the following Specifications. Buried pipes and fittings
shall also have a site or factory applied polythene sleeving. Coating shall not
be applied to pipe and fittings unless its surface is clean, dry and free from
rust. Pipe coatings shall be inspected on site and any damage or defective
areas made good to the satisfaction of the Engineer.
b) Zinc Coating
Zinc coating shall comply with ISO 8179 and shall be applied as a
spray coating. The mass of sprayed metal shall not be less than 130
g/m2 as described in Clause 5.2 of ISO 8179.
c) Bitumen Coating
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Bitumen coating shall be of normal thickness 75 microns unless

otherwise specified. It shall be a cold applied compound complying
with the requirements of BS 3416 Type II, suitable for tropical climates,
factory applied in accordance with the manufacturer's instructions.
Damaged areas of coating shall be repainted on site after removing
any remaining loose coating and wire brushing any rusted areas of
pipe.
9.5 CPVC (CHLORINATED POLY VINYL CHLORIDE) PIPES & FITTINGS
CPVC pipes & fittings solvent welded type shall be used for internal cold &
hot water supply piping work. CPVC pipes from 15mm to 50 mm shall be
Class - 1, SDR-11 confirm to the requirements of IS 15778. CPVC pipes from
65mm to 300 mm shall be schedule 40 / schedule 80 class confirm to the
requirements of ASTM-F441 & as described in the BOQ/SOQ.
CPVC fittings i.e sockets, tees, bends, reducers, brass threaded male/female
connectors, brass threaded male/female adopters unions, bushings etc shall
comply to the requirements of ASTM F438 & ASTM F439 for schedule 40 &
schedule 80 class respectively. Solvent cement for CPVC pipe shall comply
as per ASTM F493.
CPVC pipe work shall be installed strictly as per the recommendation of

manufacturer. CPVC pipe work shall be adequately supported by GI split
clamps with GI structural supports & GI threaded rods. CPVC pipe work shall
be securely tight with GI nuts, bolts & washers. Pipe work spacing shall be as
per guidance of manufacturers.
After completion of piping work, piping shall be hydraulically tested in parts

with test pumps at 10bar for 24 Hrs or 1.5 times working pressure, whichever
is higher. CPVC test plugs shall be used to seal the dead end of piping. Upon
completion of entire installations, the complete system shall be tested as
described above.
Upon successful testing of entire piping system, it shall be painted with one
coat of approved primer & two coats of approved synthetic enamel paint, as
per direction of engineer-in-charge / client.
9.5.1 CPVC Piping Installation Procedure
a) Pipe shall be cut truly straight to the required length
b) Remove burr (shaving) & clean the cut portion with dry cloth. Ensure
that jointing portion is free from any dirt, grease or any other foreign
material.
c) Install dry fit out, by inserting pipe inside the sockets upto 1/3rd to
2/3rd penetration depth. Ensure that pipe inserts to the bottom of the
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sockets, without any resistance. If pipe inserts is not to the sockets,

then check with another fittings.
d) Apply a thin coat of solvent cement to the inner side of socket upto it's
bottom & full coat to the outer side of pipe.
e) Insert pipe in to the socket, till the solvent is in fluid state. Twist the
pipe turn to cover any dry spots.
f) Hold the pipe for atleat 30 seconds, to ensure proper jointing. Wipe
out excess solvent cement with clean dry cloth.
g) Allow joint to cure for at least 24 Hours.
h) For pipe greater than 50 mm diameter, pipework shall be jointed with

primer & heavy duty solvent cement.
i) Teflon tape shall be used for threaded portion of fittings.
j) Manufacturer's recommendation shall be followed during pipe work

installations.
9.5.2 Supports Spacing
CPVC pipe work supports shall be provided as per below table.
Nominal Size Pipe Size Support Spacing (Meter) Respectively with Pipe Size
0 0 0 0
23 C 38 C 60 C 80 C
15 mm SDR 11 / SDR 13.5 1.22 / 1.22 1.22 / 1.22 1.07 / 1.07 0.92 / 0.92
SDR 11 / SDR 13.5

20 mm 1.53 / 1.53 1.37 / 1.37 1.22 / 1.22 0.92 / 0.92
SDR 11 / SDR 13.5
25 mm 1.68 / 1.68 1.53 / 1.53 1.37 / 1.37 0.92 / 0.92
SDR 11 / SDR 13.5 1.22 / 1.22
32 mm 1.83 / 1.83 1.68 / 1.68 1.53 / 1.53
SDR 11 / SDR 13.5 1.22 / 1.22

40 mm 1.98 / 1.98 1.83 / 1.83 1.68 / 1.68
SDR 11 / SDR 13.5 1.22 / 1.22
50 mm 2.29 / 2.29 2.14 / 2.14 1.98 / 1.98
65 mm SCH 40 / SCH 80 2.13 / 2.86 2.13 / 2.86 1.82 / 1.98 1.06 / 1.22
SCH 40 / SCH 80
80 mm 2.13 / 2.59 2.13 / 2.59 1.82 / 2.13 1.06 / 1.22
SCH 40 / SCH 80
100 mm 2.86 / 2.74 2.86 / 2.74 1.98 / 2.86 1.22 / 1.37
SCH 40 / SCH 80
150 mm 2.59 / 3.04 2.59 / 2.89 2.13 / 2.59 1.37 / 1.52
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9.6 VALVES & FITTINGS
9.6.1 GUNMETAL VALVES
9.6.1.1 Valves 65mm dia and below shall be heavy gunmetal full way valves or
globe valves conforming to Class I of IS: 778. Valves shall be tested at
manufacturer's works and the same stamped on it.
9.6.1.2 All valves shall be approved by the Engineer-in-Charge before they are
allowed to be used in the Work.
9.6.2 SLUICE VALVES
9.6.2.1 Unless otherwise specified all valves 80mm dia and above shall be CI
double flanged sluice valves with non rising spindle. Sluice valves shall be
provided with wheel when they are in exposed positions and with a cap top
when they are located underground. Contractor shall provide suitable
operating keys for sluice valves with cap tops.
9.6.2.2 Sluice valves shall be of approved makes conforming to IS: 780 of Class as
specified.
9.6.3 BUTTERFLY VALVES
9.6.3.1 Where specified Valves 80mm dia and above shall be cast iron butterfly
valve to be used for isolation and/ or flow regulation as directed by the
Engineer-in-Charge. The valves shall be tight shutoff/ regulatory type with
resilient seat suitable for flow in either direction and seal in both directions.
9.6.3.2 Butterfly valve shall conform to IS: 13095.
9.6.4 NON RETURN VALVE
9.6.4.1 Where specified non return valve (swing check type) shall be provided
through which flow can occur in one direction only. It shall be single door
swing check type of best quality conforming to IS: 5312.
9.6.5 FORGED BRASS BALL VALVE
9.6.5.1 Valves of size 50mm dia and below shall be full bore quarter turn lever
operated female threaded forged brass hard chrome plated ball valves
conforming to IS: 554. Valve shall have PTFE body seat rings & gland
packing, forged brass ball, stem & bonnet, carbon steel nut washer & lever
and finished in chrome. Valves shall have minimum working pressure of 16
bar. Valves shall be tested at manufacturer's works and the same stamped
on it.
9.6.6 BALL TYPE NON RETURN VALVE (NRV)
9.6.6.1 Ball type NRV shall be used in water treatment plants & sewage sump pump
piping. NRV shall be constructed in cast iron body with epoxy coating,
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phenolic resin and NBR(Nitrile) seal. NRV shall have flanged ends & can be
installed in horizontal as well as vertical position. NRV shall have minimum
working pressure of 10 bar or as per system requirements. Valves shall be
tested at manufacturer's works and the same stamped on it.
9.6.7 AIR RELEASE VALVE (ARV)
9.6.7.1 Pressurized water supply lines shall be provided with air release valve at
heighest point to release accumulated air for piping system. Air release
valve shall be automatic float operated, the diameter shall be as specified in
the BOQ. Air release valve shall be provided with ball valve for ease in
operation & maintenance. Valve body shall be in cast iron stainless steel,
brss & EPDM internal components. Valves shall have minimum working
pressure of 10 Kgs.
9.7 TESTING
9.7.1 All pipes, fittings and valves shall be tested in accordance with IS: 2065
except as may be modified herein under. All pipes, fittings and valves, after
fixing at site, shall be tested to a hydrostatic pressure of 10 kg/cm2 or 1.5
times the shut off head of the pump whichever is greater.
9.7.2 The test pressure shall be maintained for a period of at least thirty minutes
without any drop in pressure.
9.7.3 A test register shall be maintained and all entries shall be signed and dated
by Contractor(s) and the Engineer-in-Charge.
9.7.4 After commissioning of the water supply system, the Contractor shall test
each valve by closing and opening it a number of times to observe if it is
working efficiently and effectively. Valves which do not operate efficiently and
effectively shall be replaced by new ones at no extra cost and the same shall
be tested as above.
9.7.5 All pipes in wall chase or meant to be encased or buried shall be hydro tested
before the chase is plastered or the pipe encased or buried.
9.8 INSULATION
9.8.1 All open hot water flow and return pipes shall be insulated with preformed
fibrous pipe sections conforming to IS: 9842.
9.8.2 Insulation to pipes shall be with pre-moulded pipe sections, thickness for
sections shall be:
a) Pipe 50mm dia and below - 25mm thick
b) Pipe 65mm dia and above - 40mm thick
9.8.3 Application:
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a) All surfaces shall be thoroughly cleaned with a wire brush.
b) One layer of approved primer shall be applied and premoulded pipe

insulation sections shall be fixed.
c) One layer of aluminium foil of thickness 0.711mm (20 SWG), shall be

applied as a finish layer.
9.8.4 Insulation for hot water pipes in chase:
All hot water pipes in chase shall be insulated with 3 mm elastomeric tape as
per manufacturer’s recommendations.
9.9 DISINFECTION OF INSTALLATION
The water supply installation shall be disinfected as per standards and as

follows:
a) Tanks and pipes shall be filled and flushed out.
b) All bib cocks (taps) shall be closed.
c) Tanks and pipes shall be re-filled while adding a sterilizing admixture

containing 50 parts chlorine to one million parts water.
d) When the installation is filled all bib cocks (taps) shall be opened
progressively and each allowed to run until the water smells of
chlorine.
e) The installation shall be topped up and more sterilizer added.
f) The installation shall then be left for three hours and shall then be
tested for residual chlorine; if none is found, the installation shall be
drained and the process repeated.
g) The installation shall be finally drained and flushed with potable water
before use.
9.10.1 GI and CPVC pipes
a) GI pipes above ground shall be measured per linear metre (to the
nearest cm) along the centre line of the pipe and shall be inclusive of
all fittings e.g. couplings, tees, bends, elbows, unions, flanges, etc.
Deduction for valves shall be made. Rates quoted shall be inclusive of
all fittings, clamps, cutting holes chases and making good the same
and all other items mentioned in the specifications and Schedule of
Quantities.
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b) GI pipes below ground shall be measured per linear metre (to the
nearest cm) along the centre line of the pipe and shall be inclusive of
all fittings e.g. couplings, tees, bends, elbows, unions and flanges, etc.
Deduction for valves shall be made. Rates quoted shall be inclusive of
all fittings, cutting holes and chases and making good the same and
all other items mentioned in the specifications and Schedule of
Quantities. Excavation, filling, back filling with selected excavated
earth, compaction and disposal of surplus earth, fine sand filling
around GI pipes, in external work shall be measured separately, as
per respective items.
9.10.2 Valves, Bib cocks and stop cocks
9.10.3 Gunmetal and cast iron valves, Bib cocks and stop cocks shall be measured
by numbers.
9.10.4 Flanges for Nozzles
a) Flanges for nozzles shall be measured by numbers and the quoted

rate shall include welding of the flanges to the pipe nozzles.
b) Painting/ pipe protection/ insulation
Unless otherwise specified painting/ pipe protection/ insulation for

pipes shall be measured and paid for separately. These shall be
measured per linear metre along the centre line of the pipe, over the
finished surface and shall include all valves and fittings for which no
deduction shall be made.
10.0 DRAINAGE
10.1 SCOPE OF WORK
10.1.1 The scope shall include supply, installation, testing, commissioning and
satisfactory handing over of the complete water supply system to client as per
drawings, specifications and schedule of quantities.
10.1.2 Clause 8.1 shall apply to the extent applicable.
10.1.3 Without restricting to the generality of the foregoing, the drainage system
shall inter-alia include:
a) Sewer lines including earthwork for excavation, disposal, backfilling

and compaction, pipelines, manholes, drop connections and
connections to the municipal or existing sewer.
b) Storm water drainage, earth works for excavation, disposal, backfilling

and compaction, pipe lines, manholes, catch basins and connections
to the existing municipal storm water drain or connected as indicated
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10.2.2 Drainage lines and open drains shall be laid to the required gradients and
profiles.
10.2.3 All drainage work shall be done in accordance with the Local municipal bye-
laws.
10.2.4 Contractor shall obtain necessary approval and permission for the drainage
system from the municipal or any other competent Authority.
10.2.5 Location of all manholes, etc. shall be got confirmed by the Engineer-in-
Charge before the actual execution of work at site. As far as possible, no
drains or sewers shall be laid in the middle of road unless otherwise
specifically shown on the drawings or directed by the Engineer-in-Charge in
writing.
10.3 EXCAVATION
10.3.1 Alignment and grade
The sewer pipes shall be laid to alignment and gradient shown on the
drawings but subject to such modifications as shall be ordered by the
Engineer-in- Charge from time to time to meet the requirements of the Works.
No deviations from the lines, depths of cutting or gradients of sewers shown
on the plans and sections shall be permitted except by the express direction
in writing of the Engineer-in-Charge.
10.3.2 Excavation in tunnels
Excavation for sewer works shall be open cutting unless the permission of the
Engineer-in-Charge for the ground to be tunnelled is obtained in writing.
Where sewers have to be constructed along narrow passages, the Engineer-
in-Charge may order the excavation to be made partly in tunnel and in such
cases the excavated soil shall be brought back later on for refilling.
10.3.3 Opening out trenches
a) In excavating the trenches, etc. the solid road metalling, pavement,

kerbing, etc. and turf shall be placed on one side and preserved for
reinstatement after the trenches or other excavation is filled up. Before
any road metal is replaced, it shall be carefully shifted and only clean
metal used for replacing. The surface of all trenches and holes shall
be restored and maintained to the satisfaction of the Engineer-in-
Charge and of the Owners of the roads or other property traversed
and the Contractor shall not cut out or break down any live fence of
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trees in the line of the proposed works but shall tunnel under them,
unless the Engineer-in-Charge shall order to the contrary.
b) The Contractor shall grub up and clear the surface over the trenches
and other excavations of all trees, stumps roots and all other
encumbrances affecting execution of the work and shall remove them
from the site.
10.3.4 Obstruction of roads
The Contractor shall not occupy or obstruct by his operation more than one
half of the width of any road or street and sufficient space shall then be left
for public and private transit. He shall remove the materials excavated and
bring them back again when the trench is required to be refilled. The
Contractor shall obtain the consent of the concerned authority in writing
before closing any road to vehicular traffic. The foot walks must be clear at
all times.
10.3.5 Removal of filth
All night soil, filth or any other offensive matter met with during the execution
of the works, shall not be deposited on to the surface of any street or where it
is likely to be a nuisance or passed into any sewer or drain but shall be
immediately, after it is taken out of any trench, sewer or cess pool, put into
the carts and removed to a suitable place to be provided by the Contractor.
10.3.6 Excavation to be taken to proper depths
The trenches shall be excavated to such a depth that the sewer shall rest on
concrete as specified in the clauses relating thereto, so that the inverts may
be at the levels given in the sections. In bad ground, the Engineer-in-Charge
may order the Contractor to excavate to a greater depth than that shown on
the drawings and to fill up the excavation to the level of the sewers with
concrete, broken stone, gravel or other materials as directed by the
Engineer-in-Charge. Such extra excavation, concrete, broken stone, gravel
or other materials, shall be measured and paid for separately if the extra
work was ordered by the Engineer-in-Charge in writing, but if the Contractor
should excavate the trench to a greater depth than is required without a
specific order to that effect in writing of the Engineer-in-Charge, the extra
depth shall have to be filled up with cement concrete 1:4:8 (1 cement:
4coarse sand 8: stone aggregate 20mm nominal size) at the Contractor's
own costs and charges, as directed by and to the satisfaction of the
Engineer-in-Charge.
10.3.7 Refilling
After the sewer or other work has been laid and proved to be water tight, the
trench or other excavations shall be back filled with selected excavated earth
and compacted. Utmost care shall be taken in doing this, so that no damage
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shall be caused to the sewer and other permanent work. The filling in the
haunches and up to 75mm above the crown of the sewer shall consist of the
finest selected materials, as directed by the Engineer-in-Charge, placed
carefully in 150mm layers, then flooded and consolidated. After this has been
laid, the trench and other excavation shall be refilled carefully in 150mm
layers with materials taken from the excavation, each layer being watered to
assist in the consolidation unless the Engineer-in-Charge shall otherwise
direct.
10.3.8 Contractor to restore settlement and damages
The Contractor shall, at his own costs and charges, make good promptly any
settlement that may occur in the surfaces of roads, berms, footpaths,
gardens, open spaces etc. whether public or private caused by his trenches
or by his other excavations and he shall be liable for any accidents caused
thereby. He shall also, at his own expense and charges, repair and make
good any damage done to buildings and other property. If in the opinion of
the Engineer-in-Charge he fails to make good such works with all practicable
despatch, the Engineer-in-Charge shall be at liberty to get the work done by
other means and the expenses thereof shall be paid by the Contractor or
deducted from any money that may be or become due to the Contractor or
recovered from the Contractor in any other manner according to the law of
the land.
Disposal of surplus soil
The Contractor shall at his own costs and charges provide places for
disposal of all surplus materials not required to be used on the works. As
each trench is refilled the surplus soil shall be immediately removed, the
surface properly restored and the site cleared.
10.3.9 Timbering of trenches and Pits
a) The Contractor shall at all times support efficiently and effectively the
sides of all the trenches and other excavations by suitable timbering,
piling and sheeting and they shall be close timbered in loose or sandy
strata and below the surface of the sub soil water level.
b) All timbering, sheeting and piling with their wallings and supports shall
be of adequate dimensions and strength and fully braced and strutted
so that no risk of collapse or subsidence of the walls of the trench
shall take place.
c) The Contractor shall be held responsible and shall be accountable for

the sufficiency of all timbering, bracing, sheeting and piling used and
also for, all damage to persons and property resulting from improper
quality, strength, placing, maintaining or removing of the same.
10.3.10 Shoring of buildings

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The Contractor shall shore up all buildings, walls and other structures, the
stability of which is liable to be endangered by the execution of the work
and shall be fully responsible for all damages to persons or property
resulting from any accident.
10.3.11 Removal of water from sewer, trench etc.
The Contractor shall at all times during the progress of the work keep the
trenches and excavations free from water which shall be disposed of by
him in a manner as shall neither cause injury to the public health nor to the
public or private property nor to the work completed or in progress nor to
the surface of any roads or streets nor cause any interference with the use
of the same by the public at no extra cost.
10.3.12 Width of trench
a) The Engineer-in-Charge shall have power by giving an order in

writing to the Contractor to increase the maximum width/ depth in
respect of which payment shall be allowed for excavation and back
filling in trenches for various classes of sewer, manholes, and other
works in certain lengths to be specifically laid down by him, where
on account of bad ground or other unusual conditions, he considers
that such increased widths/ depths are necessary in view of the site
conditions.
b) The width of trenches at the bottom shall be as follows:-
100mm dia pipe - 550mm
225-250mm dia pipe - 600mm
Maximum width of the bed concrete shall also be as above. No

additional payment is admissible for widths greater than specified
unless directed by the Engineer-in-Charge as given in clause above.
10.4 SALT GLAZED STONEWARE PIPES
10.4.1 Stoneware pipes shall be new and of first Class quality salt glazed and free
from rough texture inside and outside and straight. All pipes shall comply with
IS: 651 and have the manufacturers name marked on them.
10.4.2 Laying of salt glazed stoneware pipes
a) Pipes are liable to be damaged in transit and not withstanding tests

that may have been made before despatch each pipe shall be
examined carefully on arrival at site. Each pipe shall be lightly struck
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with a wooden hammer or mallet and those that do not ring true and
clear shall be rejected. Sound pipes shall be carefully stacked to
prevent damage. All defective pipes shall be segregated, marked in a
conspicuous manner and their use in the works prevented by
expeditiously removing them from the work site.
b) The pipes shall be laid with sockets leading uphill and should rest on
solid and even foundations for the full length of the barrel. Socket
holes shall be formed in the foundation sufficiently deep to allow the
pipe jointer room to work right round the pipe and as short as
practicable to admit the socket and allow the joint to be made.
c) Where pipes are not bedded on concrete the trench bottom shall be
left slightly high and carefully bottomed up as pipe laying proceeds so
that the pipe barrels rest on firm ground. If excavation has been
carried too low it shall be made up with cement concrete 1:4:8 (1
cement: 4coarse sand: 8 stone aggregate 20mm nominal size) at the
Contractor's cost and charges.
10.4.3 Jointing of salt glazed stoneware pipes
a) Tarred gaskin shall first be wrapped round the spigot of each pipe and
the spigot shall then be placed into the socket of the pipe previously
laid, the pipe shall then be adjusted and fixed in its correct position
and the gaskin caulked tightly home so as to fill not more than one
quarter of the total length of the socket.
b) The remainder of the socket shall be filled with stiff mix of cement
mortar (1 cement: 1 clear sharp washed sand). When the socket is
filled, a fillet shall be formed round the joint with a trowel forming an
angle of 45 degrees with the barrel of that pipe. The mortar shall be
mixed as needed for immediate use and no mortar shall be beaten up
and used after it has begun to set.
c) After the joint has been made any extraneous materials shall be
removed from the inside of the joint with a suitable scraper of
"badger". The newly made joints shall be protected until set, from the
sun, drying winds, rain or dust. Sacking or other materials which can
be kept damp shall be used. The joints shall be exposed and space
left all around the pipes for inspection by the Engineer-in-Charge. The
inside of the sewer must be left absolutely clear in bore and free from
cement mortar or other obstructions throughout its entire length, and
shall efficiently drain and discharge.
d) In case Glazed Stoneware pipes are jointed with rubber rings as per
BOQ, the rubber ring shall confirm to IS-5382.
10.4.4 Gully traps
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a) Gully traps shall be of the same quality as described for stoneware

pipes under clause 10.4.1.
b) Gully traps shall be fixed in a masonry chamber as per specifications.

The CI sealed cover and frame shall weigh not less than 7.3 kg.
Where necessary, sealed cover shall be replaced with CI grating of
the same size.
10.5 REINFORCED CEMENT CONCRETE PIPES
10.5.1 All underground storm water drainage pipes and sewer lines where specified
(other than those specified as cast iron) shall be centrifugally spun S&S RCC
pipes of specified Class conforming to IS: 458. Pipes shall be true and
straight with uniform bore, throughout. Cracked, warped pipes shall not be
used on the work. All pipes shall be tested by the manufacturer and the
Contractor shall produce a certificate to that effect from the manufacturer.
10.5.2 Laying
RCC S&S spun pipes shall be laid on cement concrete bed or cradles as
specified and shown on the detailed drawings. The cradles may be pre cast
and sufficiently cured to prevent cracks and breakage in handling. The invert
of the cradles shall be left 12mm below the invert level of the pipe properly
placed on the soil to prevent any disturbance. The pipe shall then be placed
on the bed concrete or cradles and set for the line and gradient by means of
sight rails and bonding rods etc. Cradles or concrete bed may be omitted, if
10.5.3 Jointing of pipes
Jointing of RCC pipes with collar joint shall be with CM (1:1) after inserting
bitumen gasket in between groove of pipes as per the details given in cl.
10.4.3. In case of spigot-socket RCC pipes jointed with rubber rings as
specified in BOQ, the rubber rings shall conform to IS: 5382.
10.6 CEMENT CONCRETE AND MASONRY WORKS (for manholes and

chambers etc.)
10.6.1 Materials
All materials used in cement concrete and masonry works e.g., water, coarse
aggregates, sand, cement, reinforcement bars, bricks etc. shall conform to
relevant Indian Standards and the Specifications of the Central Public Works
Department.
10.6.2 Cement concrete for pipe support
a) Wherever specified or shown on the drawings, all pipes shall be

supported on a bed, all around or in haunches. The thickness and mix
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of the concrete shall be as given in the Schedule of Quantities. Width

of the bedding shall be as per clauses under 10.3.12.
b) RCC pipes or CI pipes shall be supported on brick masonry or pre

cast RCC or in situ cradles as shown on the drawings or as directed
c) Pipes in loose soil or above ground shall be supported on brick or

stone masonry pillars as shown on the drawings or as directed by the
Engineer-in-Charge.
d) Unless otherwise directed by the Engineer-in-Charge cement concrete

for bed, all around or in haunches shall be laid as follows:-
Classification
Upto 1.5m Upto 3m Beyond 3m
of Pipe
Depth Depth Depth
support
Stoneware
pipes in open All round In haunches In haunches
ground (no sub (1:5:10) (1:5:10) (1:5:10)
soil water)
RCC or SW in All round In haunches In haunches

sub soil water (1:3:6) (1:3:6) (1:3:6)
CI Pipes (in all All round In haunches In haunches

conditions) (1:3:6) (1:3:6) (1:3:6)
RCC Pipes or
All round All round All round
CI pipes under
(1:3:6) (1:3:6) (1:3:6)
building
RCC / CI
/Stoneware All round All round All round
Pipes under (1:3:6) (1:3:6) (1:3:6)
road
(1=cement, 3/5=coarse sand, 6/10=stone aggregate40mm nominal

size)
10.7 MANHOLES AND CHAMBERS
10.7.1 All manholes, chambers and other such works as specified shall be
constructed in brick masonry in cement mortar 1:4 (1 cement: 4 coarse sand)
or as specified in the Schedule of Quantities.
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10.7.2 All manholes and chambers, etc. shall be supported on base of cement
concrete of such thickness and mix as given in the Schedule of Quantities or
shown on the drawings.
10.7.3 Where not specified, manholes shall be constructed as follows:-
Size / type of 900x450 900x600 900 dia 1200 dia 1500 dia
manhole Rect. Rect. Conical Conical Conical
450 to 1200 to 1650 to 2300 to

Depth in mm 600 to 1200
600 1650 3000 9000
Size of cover 900x450 900X600 600 dia 600 dia 600 dia
Weight of DI 115 kg 130 kg 130 kg 130 kg
135 kg
frame and medium medium medium medium
medium duty
cover duty duty duty duty
Note - All dimensions are clear internal dimensions in mm. In case of SFRC
frame and cover is specified / mentioned in BOQ, it shall conform to
IS: 12592.
10.7.4 All manholes shall be provided with cement concrete benching in 1:2:4
nominal mix. (1 cement: 2 coarse sand: 4 stone aggregate 20mm nominal
size). The benching shall have slope of 1:12 towards the channel. The depth
of the channel shall be full diameter of the pipe. Benching shall be finished
with a floating coat of neat cement with water proofing compound.
10.7.5 All manholes shall be plastered with 12/15mm thick cement mortar 1:3 (1
cement: 3 coarse sand) and finished with a floating coat of neat cement
inside. Manhole shall be plastered outside as above but with rough plaster
with waterproofing compound.
10.7.6 All manholes with depths greater than 1 m. shall be provided with 20mm
square or 25mm round CI/Polypropylene footrests set in cement concrete
blocks 250x100x100m min 1:2:4 mix (1 cement: 2 coarse sand: 4 stone
aggregate 20mm nominal size), at 300mm centre to centre vertically and
staggered. Footrests shall be coated with coal tar before embedding.
10.7.7 All manholes shall be provided with cast iron covers and frames and
embedded in reinforced cement concrete slab. Weight of cover, frame and
thickness of slab shall be given above.
10.8 MAKING CONNECTIONS
10.8.1 Contractor shall connect the new sewer line to the existing manhole by cutting
the walls, benching and restoring them to the original condition. A new
channel shall be cut in the benching of the existing manhole for the new
connection. Contractor shall remove all sewage and water if encountered in
making the connection without additional cost. Back filling and compaction
shall be done carefully in layers, simultaneously on both sides so as to
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prevent unequal earth pressure. Back filling shall not be taken up till testing
has been successfully completed.
10.9 TESTING
10.9.1 All testing shall be done in accordance with IS: 1172 and IS: 5329 except as
may be modified herein under.
10.9.2 All lengths of the sewer/ drain/ pipelines shall be fully tested for water
tightness by means of water pressure. Testing shall be carried out from
manhole to manhole. All pipes shall be subjected to a test pressure of at least
2.5m head of water. The test pressure shall, however, not exceed 6m head at
any point. The pipes shall be plugged preferably with standard design rubber
plugs on both ends. The upper end shall, however, be connected to a pipe for
filling with water and getting the required head. The sewer/ drain/ pipeline
shall be filled with water and left to stand for 2 hours and topped up. The
leakage over 30 minutes shall then be measured and the loss in water shall
not exceed 2 litres/cm. of diameter/km of pipeline measured during the last 10
minutes of the period of test.
10.9.3 Sewer lines shall be tested for straightness by:
a) Inserting a smooth ball 12mm less than the internal diameter of the
pipe. In the absence of obstructions such as yarn or mortar projecting
at the joints the ball should roll down the invert of the pipe and emerge
at the lower end,
b) Means of a mirror at one end and a lamp at the other end. If the pipe
line is straight the full circle of light shall be seen otherwise obstruction
or deviation shall be apparent.
10.9.4 A test register shall be maintained which shall be signed and dated by the
Contractor and the Engineer-in-Charge.
10.9.5 The pipeline shall be covered only after the testing is successfully completed.
10.10.1 Excavation
a) Measurement for excavation of pipe trenches shall be made per linear

metre under the respective category of soil classification encountered
at site.
i) Ordinary soil
ii) Hard soil (hard murrum and soft rock)
iii) Hard rock requiring chiselling
iv) Hard rock requiring blasting.

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b) Trenches shall be measured between outside walls of manholes at top

and the depth shall be the average depth between the two ends to the
nearest centimetre. The rate quoted shall be for a depth up to 1.5m or
as given in the Schedule of Quantities.
c) Payment for trenches more than 1.5m in depth shall be made for extra
depth as given in the Schedule of Quantities over and above the rate
for depth upto1.5m.
d) The original ground levels shall be jointly recorded prior to start of

work.
10.10.2 Timbering and Shoring
Timbering and shoring provided shall be paid as specified in schedule of

quantities unless noted otherwise.
10.10.3 Saturated Soil
Rate quoted for excavation shall be inclusive of pumping and bailing out of
water encountered from any source whatsoever.
10.10.4 Refilling, Consolidation and Disposal of Surplus Earth
Rate quoted for excavation shall be inclusive of refilling, consolidation and

disposal of surplus earth.
10.10.5 Stoneware/ RCC/ CI pipes
Stoneware/ RCC/ CI pipes shall be measured for the finished length of the
pipeline per linear meter to the nearest centimetre i.e.
a) Lengths between manholes shall be recorded from inside face of

one manhole to inside face of next manhole,
b) Length between gully trap and manhole shall be recorded

between socket of pipe near gully trap and inside face of manhole.
Rate shall include all items given in the Schedule of Quantities
and specifications.
10.10.6 Gully Traps
Gully traps shall be measured by the number and rate shall include all
excavation, back filling, foundation, concrete brick masonry, cement plaster
inside and outside, CI grating and sealed cover and frame etc. complete.
10.10.7 Cement Concrete for Pipes
Cement concrete in bed and all around or in haunches shall be paid on

cubic metre basis as per the drawing. No additional payment is admissible
in respect of concreting done for widths greater than that specified, for
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shuttering or centering, concreting and curing or work in subsoil water

conditions.
10.10.8 Manholes
a) All manholes shall be measured by numbers and shall include all

items specified above and necessary excavation in all types of soils,
refilling, compaction and disposal of surplus earth.
b) Manholes with depths greater than that specified under the main item
shall be paid for under "extra depth" and shall include all items as
given for manholes. Measurement shall be done to the nearest
centimetre. Depth of the manholes shall be measured from top of the
manhole cover to invert level of channel.
c) C. I. covers, frames & steps shall be paid separately as per schedule

of quantities.
10.10.9 Making Connections
Item for making connection to municipal sewer shall be paid for by number
and shall include all items given in the Schedule of Quantities and
specifications.
END
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TCE.M4-403-06 SPECIFICATIONS FOR SHOTCRETING AND GUNITING SHEET 1 OF 7
1. SCOPE
1.1. This Specification covers the general requirements of materials, mixing,
placing, curing, constructional and other performance related requirements of
encasing the structural steel members for fire proofing (thickness less than
75mm) as well as strengthening & rehabilitation of concrete structures using
Shotcreting and Guniting. Any other special requirement specified by
ENGINEER or OWNER or as indicated on the drawings shall supersede the
requirements given in this document.
1.2. In addition to this specification, guniting shall be carried out in accordance
with IS: 9012 and other relevant codes mentioned therein. In case of any
conflict between this document and IS codes, the requirements given in this
document shall govern.
2. MATERIALS
All materials to be used for shotcreting shall conform to the requirements of
IS codes. Samples and test results of all materials shall be submitted to
ENGINEER or OWNER for approval. The source of materials shall be kept
same during the execution of the project.
2.1. Cement shall conform to IS 269 or IS 455 or IS 1489, IS 8041 or IS 8112.
2.2. Sand shall comply with the requirements of IS 383 and graded evenly from
fine to coarse as per Zone II and III. Sand of Zone IV shall not be used.
2.3. Coarse aggregates when used shall comply with the requirement of IS 383.
Maximum size of aggregates shall be 10mm. The grading of aggregate shall
be as per IS 9012.
2.4. Water – It shall comply with the requirements of IS 456.
2.5. Admixture – It shall comply with requirements of IS 9103. This shall be mixed
with concrete strictly as per manufacturer’s recommendations and shall meet
the requirements of IS 456.
2.6. Welded wire fabric to be used as reinforcement, shall conform to IS: 1566
and shall be of approved type. Welded wire mesh size shall be 50mmx50mm
and diameter of wire shall not be more than 3mm.
2.7. Reinforcement bars, wherever required shall conform to IS 1786 and
maximum dis meter of reinforcement bar shall not be more than 16mm.
2.8. Air used, shall be dry and free from chemical or hydrocarbon or acid fumes
and smoke.
3. SHOTCRETE PROCESS
Shotcreting shall be done by any of the following two processes.
3.1. Dry Mix Process
Moist sand / coarse aggregates with optimum moisture content of 3% to 6%
shall be thoroughly mixed with cement in a mixing chamber and further fed in
to a special mechanical feeder / dispensing gun. The mixture shall be forced
in to the delivery hose by a feeder week / distributor. The mixed material
shall be kept in suspension by compressed air. The gun shall be connected
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to a water pressure system through a regulating valve controlling the ratio of

water with dry mix as per approved mix design. The mortar shall be jetted
from the nozzle at high speed on the surface. Quantity of water shall be such
that the losses due to rebound are kept minimum and also prevent dusting
and blowing of the material. It shall ensure deposition of dense gunite on the
surface without sagging.
3.2. Wet Mix Process
Water shall be thoroughly mixed with aggregates and cement in the mixing
drum in wet mix process and the mortar shall be fed in to the chamber of the
delivery equipment. The mixture shall be passed under pressure from the
delivery chamber to the nozzle. Compressed air shall be injected along with
the mixture at the nozzle point to increase the velocity and improve the
shooting pattern. The mortar shall be jetted from the nozzle at high velocity
on to the surface.
3.3. All the equipment and accessories required for guniting shall be from
approved manufacturer, adequate capacity and well tried & tested type. The
various equipment to be used for dry or wet mix processes are as follows.
a) Mixing equipment (Self Cleaning)
b) Guniting equipment conforming to IS 6433 for dry mix process.
c) Air Compressor for air supply (Non-Pulsating type) including moisture
extractor for supply of dry air, pressure gauge near the outlet nozzle.
d) Pressurized water line to maintain the pressure at the discharge nozzle
higher than operating air pressure including online pump to maintain the
pressure in case of any fluctuation.
e) Delivering equipment of adequate capacity as recommend by
manufacturer
4. SURFACE PREPARATION
4.1. Refer TCE.M4-405-06 for fire proofing of steel structures.
4.2. Surface Preparation for Strengthening & Rehabilitation of Concrete members
a) Grease, oil, algae and other foreign substances likely to impair good
bonding shall be thoroughly removed from the surface by scrubbing
or using detergent and washing with clean water.
b) All loose and disintegrated concrete shall be removed carefully by
chipping using chisel or hammer to expose the sound concrete
surface and rusted reinforcement, if any. Care shall be taken to leave
sound and compact concrete undisturbed and to ensure that any
good bond between the embedded reinforcement and parent
concrete is not broken.
c) The surface to shotcreted or gunited shall be made rough by
chiselling and taking of the upper layer of the concrete till the sharp
edges of the aggregates are exposed. Such surface shall be washed
and wetted and kept damp prior to shotcreting or guniting. The
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peripheral edges of broken concrete shall be cut to true and in

rectilinear patterns.
d) Re-entrant/angled corners shall be chamfered. Plaster or coating, if
any, shall be removed to the extent beyond the cut edges of the
damaged concrete. Any inherent honeycombing, voids, cavities etc.
shall be grouted. All unwanted foreign materials shall be removed by
wire brushing and washing with a water jet.
e) Any existing reinforcement reduced in size, beyond acceptable limits
and certified as such by the consultant, shall be cut and removed.
The remaining reinforcement shall be cleaned thoroughly of all
scales, rust and blemishes by light chipping and scrubbing with wire
brush. An approved rust remover shall be used if so instructed by the
consultant.
a) Exposed reinforcement shall be cleaned with wire brushes. Layer of
welded wire fabric and or other reinforcements as shown on the
drawings shall be fixed to the firm concrete by means of clips or tie
wire. These fixing clips shall be grouted in the drilled holes on the
existing concrete by means of cement sand mortar in 1:2 proportions
or suitably welded with exposed reinforcements. The welded wire
fabric shall be tied with these clips at suitable intervals by means of
16SWG black annealed wire. All care shall be taken so that the
welded wire mesh or other reinforcements remain in their positions
during the process of shotcreting.
b) Any dislodged but acceptable reinforcement shall be anchored by
means of dowels secured in the parent concrete, locking the
reinforcement in position as shown in detailing sketches and/or as
c) The minimum clearance between the wire fabric and form of back up
materials shall be 12mm.
d) Where shotcreting / guniting is specified to strengthen the existing
work, additional reinforcement conforming to IS 1786 shall be
provided.
5. MIXING, APPLYING and CURING
5.1. Shotcreting / Guniting shall be carried out by a specialized agency having
sufficient experience. Only skilled and experienced operator shall be
employed for the purpose. Capability of nozzle men shall be qualified initially
and also during the tenure of the work as per IS 9012.
5.2. Before start of the application, pipes, equipment etc. in the vicinity of the work
area shall be covered to protect them during the process. Open end of the
pipe shall be covered by suitable shielding materials.
5.3. In order to fix the dimensions of members such as columns and beams,
shooting strips shall be fixed along the edges and to the desired levels and
plumb. The gunite shall be applied in two stages. Gunite mortar is first filled
behind the shooting strips, and allowed to acquire initial set. The edges of the
first stage are roughened and any entrapped rebound is removed so that a
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satisfactory construction joint is built up. The remaining area between the
shooting strips is then filled to the level and line of the shooting strips.
5.4. Mix to be used shall conform to the strength requirement as specified in IS
456. Contractor shall submit mix design to ENGINEER or OWNER for
approval. The minimum crushing strength of 24N/mm2 at 28 days shall be
ensured prior to start of the work. Admixtures can be added with prior
approval of ENGINEER or OWNER in the design mix to achieve required
design parameters.
5.5. The water cement ratio of dry mix guniting shall be in the range of 0.3 to 0.5
by weight and 0.4 to m to 0.55 for wet mix.
5.6. The air pressure at the gun outlet shall not be less than 3 kg/cm2.The air and
water pressure shall be uniform and steady. However, the pressure may be
slightly adjusted depending upon the location of the surface, Nozzle size and
orientation etc. to ensure proper deposition and consolidation of the materials
with minimum wastage.
5.7. The application of gunite mortar shall be governed by uniform delivery,
consistent proportion and grading of mix, control of water to assure minimum
of dusting and rebound as well as maximum bonding to present concrete. The
critical part of the total application is nozzle operation and spraying technique.
The proper method of application is to begin at the lowest point, filling in the
corners and recesses first and then to fill the main body of the section in
layers by systematic movement of the nozzle is the ideal spraying method.
Care must be taken to avoid sand pockets behind reinforcement bars. Initially,
the coarse sand particles rebound from the surface and a grout of fine sand
and cement which is also very rich in cement (1:1.5 cement: sand) is built up
on the surface of concrete. This grout helps bonding of gunite to concrete and
also forms a soft cushion for receiving the gunite spray from the nozzle. The
rebound reduces considerably and gunite is built up on the surface in layers.
Any humps in the last layer of gunite should be cut by the edge of a steel
trowel to level the gunite. Finally, a spray coat of gunite with fine sand and
cement is applied to ensure good surface density an impervious to gunite.
5.8. Shotcreting or Guniting shall be laid to a maximum thickness of 50mm in one
operation. Where a layer of shotcreting is to be covered by succeeding layers,
the successive layer shall be laid only after the initial set of previous layer. All
loose materials shall be removed by brooming or hacking and surface e be
cleaned with water jet. The surface shall be thoroughly checked by a hammer
for hollow areas resulting for rebound pockets in poor bond. Such areas shall
be cut and replaced during the second layer deposition.
5.9. When shotcrete consists of several layers, concrete delivery shall be so
scheduled so that each layer is placed while the preceding one is still plastic
to avoid cold joints. If the underlying layer has stiffened just beyond the point
where it can be penetrated by the vibrator, bond can still be obtained by
thoroughly and systematically vibrating the new concrete into contact with the
previously placed concrete; however, an unavoidable layer line will show on
the surface when the form is removed.
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5.10. When multiple layers of wire fabric are required, the first layer is covered with
shotcrete prior to placing the next layer, with ties extending from the first layer
to the next. At least one layer of fabric is used for each 2 inches of shotcrete.
5.11. When applying more than one layer of shotcrete, use a cutting rod, brush with
a stiff bristle, or other suitable equipment to remove all loose material,
overspray, laitance, or other material that may compromise the bond of the
subsequent layer of shotcrete. If shotcrete has hardened, clean the surface of
all loose material, laitance, overspray, or other material that may compromise
the bond of subsequent layers. Bring the surface to a saturated surface-dry
condition at the time of application of the next layer of shotcrete.”
5.12. The nozzle shall be held in optimum position usually between 0.5 to 1.5m
from and at the right angle to the surface.
5.13. The thickness of coating established by providing ground wires both in
vertical and horizontal directions. Ground wires shall be tight and true to line
and placed in such a manner that they can be further tightened if required.
5.14. During application of shotcrete, cement mortar which rebounds off the surface
shall not be used again.
5.15. Construction joints shall be provided at the end of each day’s work or on
stopping work for any reason by tapering the mortar coating to a thin edge
within a length of 300mm. Work shall commence only after cleaning and
wetting of the surface.
5.16. The coating shall be cured by keeping it moist for a period of eight hours and
for a period of at least 7 days or else surface shall be coated with membrane
curing compound. Membrane curing compound shall be from approved
manufacturer.
6. FINISHING AND JOINT SEALING
6.1. The final flush coat 3 to 6mm thick shall be applied to the fresh screeded
lightly wetted surface of the shotcrete and shall be troweled smooth.
6.2. If sufficient cover (at least 25 mm.) is provided on the outer layer of
reinforcement, then gunite does not need any additional protection. However,
the natural finish of gunite is equivalent to rough cast plaster. If smooth
finished surface is required, then additional plaster shall be provided as per
the drawings or directed by an ENGINEER. Plaster shall be applied only after
seven days curing of gunite.
7. APPROACH, WORKING PLATFORM, SCAFFOLDING & FORMWORK
7.1. The contractor shall arrange all approaches, Accesses, scaffoldings,
stairways, ladders, working platform etc. for carrying out the shotcreting /
Guniting process safely. The working area shall be neatly maintained and all
the facilities required by the ENGINEER or OWNER for supervision shall be
provided by the contractor. All temporary works shall be removed by
contractor after satisfactory completion of work and after approval of
ENGINEER or OWNER.
7.2. Formwork, wherever required shall be of plywood. It shall be adequately
supported and braced to protect against deformation on account of vibration
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during the application. Forms shall be oiled, dampened and cleaned before
use.
8. PRECONSTRUCTION AND QUALITY CONTROL
8.1. Test panels simulating actual working conditions shall be fabricated by the
operating staff, using the equipment, material and mix proportion, water
cement ration, etc. as proposed for the main job. These panels shall be
fabricated by gunning on to a back form of plywood. Separate panels shall be
fabricated for different mix proportions being proposed and also for each
gunning position to be encountered during the actual working. The size of
panel shall not be less than 750mm x 750mm and the thickness of guniting /
shotcreting shall be 75mm. Part of the panel shall contain the same
reinforcement as proposed to ascertain soundness of concrete behind the
reinforcement. Panel size shall be large enough to ensure quality and
uniformity of the operation.
8.2. Cubes or cores shall be taken from the panel for testing. The core shall have
a minimum diameter of 75mm. The specimen shall be tested at the end of 7
and 28 days as per relevant IS code of testing cores. Only 28 days strength
shall be considered as strength acceptance criteria.
8.3. The cut surface of the core shall be carefully examined and additional surface
shall be exposed by sawing or breaking the panel to check the soundness
and uniformity of the material. All cut or broken surfaces shall be dense and
free from laminations and sand pockets.
8.4. Small un-reinforced test panels, at least 300 mm x 300 mm x 75 mm thick
shall be periodically gunned and cores or cubes extracted for compressive
tests and visual examination.
8.5. Test core shall also be taken from the completed work at regular periods as
decided by the ENGINEER or OWNER to ensure that control tests reflect the
actual quality.
8.6. Cubes, by directly gunning in to 150mm cube moulds shall be taken from day-
to-day quality tests. The results of core tests shall be co-related to the results
of cubes made from the panels. Frequency of sampling of shotcrete and
acceptance criteria shall be as decided by the ENGINEER.
9. PAYMENT
9.1. Payment for encasing structural steel members for fire proofing shall be
regulated as per the payment clauses given specification M4-405-06.
9.2. Payment for strengthening and rehabilitation of concrete structures shall be
made as mentioned below.
a) Payment shall be made on cubic metre (m3) basis of actually finished
work as certified by ENGINEER.
b) The rate quoted shall be inclusive of all labour
c) The rate quoted shall be inclusive of all labour, material, form work,
plant & tools etc. required for the successful and satisfactory completion
of work including curing, curing compound, all cleaning operations
FILE NAME:

before and after the work, preparation of the surface as specified,

applying the primer coat compatible with the primer already applied over
nuts and effected surface of steel surfaces due to welding , finishing the
surface smooth, painting the surface with 2 coats of micro-porous
exterior top coats & sealing the joints with sealing compounds,
providing required access, working platforms, props, scaffolding and
other safety measures including their removal after completion.
d) Reinforcement (Welded wire fabric / reinforcing bars) wherever used
shall be paid extra. The rate shall be inclusive of supplying and fixing
reinforcement bars, binding wires, clips etc. required for satisfactory
completion of the work.
e) The rates quoted shall be inclusive of the tests specified and directed
to establish the quality and strength of materials.
END
FILE NAME:

SPEC. NO.
TCE.M4-405-06 SPECIFICATION FOR
SHEET 1 OF 6
FIRE PROOFING OF STEEL STRUCTURES
1. SCOPE
1.1. This specification covers the general requirements of materials and the
method of application for external fire protection of structural steel
members, vessel/column skirts, saddles and supports against fire by
shotcreting, in-situ concrete or vermiculite cementitious coating.
1.2. This specification does not cover the general requirements of materials
and the method of application for external fire protection of structural steel
members, using intumescent paint. Intumescent paint, if applied, shall
conform to the requirements of IS 17044.
2. MATERIALS
2.1. All materials to be used shall conform to the requirements of respective latest
BIS codes. Samples and test results for all materials shall be submitted to the
ENGINEER or OWNER and got approved from him in writing before
execution of work. Acceptance criteria of commonly used materials are given
below.
2.1.1. Cement - The cement used shall conform to either of the following BIS codes:
a) 33 Grade ordinary Portland cement conforming to IS: 269.
b) Portland slag cements conforming to IS: 455.
c) Portland pozzolana cement (fly ash based) conforming to IS: 1489

(Part-I)
d) 43 Grade ordinary Portland cement conforming to IS: 8112
e) Sulphate resisting Portland cement conforming to IS: 12330.
disclosure of the contents to anyone outside TCE is strictly prohibited except with the prior written consent from TCE
R0

SPEC. NO.
SHEET 2 OF 6
2.1.2. Fine Aggregates (Sand) - Sand shall comply with the requirements of IS 383
and graded evenly from fine to coarse as per Zone II and Zone III. Sand of
Zone IV shall not be used.
2.1.3. Coarse Aggregates – Coarse aggregates shall comply with the requirements
of IS 383. Maximum size of aggregates shall be 10mm for shorcrete
application. For cast in situ application, higher size of aggregates as per IS
9102 may be used.
2.1.4. Water – It shall comply with the requirements of IS 456.
2.1.5. Admixture – It shall comply with requirements of IS 9103. This shall be mixed
with concrete strictly as per manufacturer’s recommendations and shall meet
the requirements of IS 456.
2.1.6. Vermiculite Cementitious Coating - Branded product with a base as

vermiculite and mixed with ordinary Portland cement shall have a maximum
loose dry density of 400 kg/m3 and in moulded condition, density shall not
exceed 800 kg/m3. Sulphate content in the branded product shall not exceed
1% when sulphate content is expressed as sulphur trioxide.
2.1.7. Expanded Metal Steel Sheet - Expanded metal steel sheets shall conform to
IS: 412 and shall be of an approved type. Size of the mesh shall be
10mmx40mm with strands of 2.5mm width and 1mm thickness.
2.1.8. Reinforcement - Welded wire fabric to be used as reinforcement, shall

conform to IS: 1566 and shall be of approved type. Mesh size shall be
50mmx50mm and thickness of wire shall be 3mm.
2.1.9. Accessories
i. Binding Wire: Binding wires shall be of mild steel, not thinner

than 16 SWG
ii. Nuts: Nuts shall be made of mild steel and shall conform to
IS:1367 and IS:2585.
iii. Cover plates: Cover plates shall conform to IS: 2062 Quality-
A/BR; Grade E250/E350; killed and tested for impact resistance.
iv. Bitumen Mastic flashing - Bitumen mastic flashing shall
conform to IS: 3037
3. SURFACE PREPARATION
3.1. Surface cleaning
All steel surfaces to be in contact with the fire proofing coating material,
shall be cleaned of all oil, grease, loose rust, scales and dust by using
wire brushing and washing using detergents.
3.2. Welding of nuts and application of primer
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SPEC. NO.
SHEET 3 OF 6
Nuts of M16 bolts shall be welded with all the steel members to be fire
proofed. Maximum spacing of nuts shall be 400mm centre to centre in both
directions. Nuts shall not be welded to the vessel supports/skirts (to be
welded by vessel fabricator); unless directed by ENGINEER or OWNER.
Primer paint shall be applied to the MS nuts and affected surfaces of
the members due to welding after proper cleaning. Primer paint shall
be compatible with the primer already applied to the steel members.
3.3. Fixing of expanded metal steel sheet
Expanded metal steel sheet shall only be used for built up sections,
consisting of two members spaced apart. This shall be kept in position
true to line and face, and shall be attached firmly to structural steel
member by tack welding or with the help of clips and 16 SWG tying wire at
300mm centre to centre. Minimum lap of 75mm shall be provided wherever
required, however laps shall be avoided at bends. Strands of the expanded
metal steel sheet shall slope inwards & downwards.
3.4. Placement of reinforcement
Reinforcement shall be placed in the middle of coated material thickness. It
shall be bent confirming with outlines of finished encasement and rigidly
secured in place by tie wire with all the nuts. Minimum lap at ends and sides
shall be 100mm and lapped wire fabric shall be tied firmly.
3.5. Cover plate
Cover plates shall be welded to the top flange of the beams if top edges of
fire proofing are not protected with bitumen mastic flashing
4. APPLICATION
4.1. Application of fire proofing material coating (Shotcreting / Guniting) shall be

carried out by skilled and experienced operators.
4.2. Before start of application, pipes and equipment in the vicinity shall be
covered with polythene/tarpaulin to protect them against damage. Open
end of pipes shall be covered with wooden plugs or with other suitable
shielding materials.
4.3. Steel sections up to and including 300mm depth, shall be coated by solid fill
while sections more than 300mm shall be coated in the shape of profile of
sections as shown in sketches. For vessel skirts, columns and saddles of
horizontal vessels, the coating material shall be applied in horizontal bands
working upwards from the bottom of the skirt or column I saddle base plate.
All outside edges of the fire proofing shall be champhered by 20mm except
for shotcreting, corners shall be rounded.
4.4. Thickness of fire proof coating shall be established by providing ground wires
both in vertical and horizontal directions. Ground wires shall be tight and true
to line, and placed in such a manner that they can be further tightened if
required.
4.5. The fire proofing material, after application, shall be cured by keeping it in
moist condition for a period of at least 14 days or else the surface shall be
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SPEC. NO.
SHEET 4 OF 6
coated with a membrane of approved curing compound. Brand name, name

of manufacturer, test results and method of application shall be submitted to
and got approved from the ENGINEER or OWNER prior to procurement of
curing compound.
5. APPROACH, W O R K I N G PL ATFO RM , SCAFFOLDING & FORM

WORK
5.1. The Contractor shall arrange all approaches, scaffolding, stair ways, ladder,
working platform etc., for carrying out the entire works s af e l y . The working
area shall be neatly maintained and all the facilities required by ENGINEER
or OWNER for proper supervision of the work shall be provided. In case,
any special precaution is needed for the safety of the structure till the
completion of application, the Contractor shall make and provide all such
arrangement to the complete satisfaction of the ENGINEER or OWNER and
shall remove the same after completion of works.
5.2. Form work wherever required shall be of Plywood Sheeting. It shall be
adequately supported and braced to protect against deformation on account
of vibration during the application. Forms shall be oiled, dampened and
cleaned before use. All other specifications pertaining to the f o r m work
shall be as per specification M4-403-01.
6. SPECIFIC REQUIREMENT
6.1. Fire-proofing by shotcreting
Material, equipment and method of application shall be in accordance with TCE

specification no M4-403-06 as well as with the foregoing clauses 2.0 to 5.0.
Thickness of concrete coating over the steel shall be 50mm.
6.2. Fire-proofing b y in-situ concrete
Concrete for fireproofing shall be of M20 grade design mix. Mixing and
placing shall be done as per TCE specification no. M4-403-01. Thickness of
concrete coating over the steel shall be minimum 50mm.
Concrete shall be poured into well-made forms properly oiled and made
to correct dimensions. . Concrete shall be vibrated as necessary to
ensure smooth surface, free from voids and irregularities. Any defects,
honeycomb etc. shall be made good by contractor at his own cost.
6.3. Vermiculite cementitious coating
6.3.1. Design
a) Vermiculite cementitious coating shall restrict the temperature of a

vessel/structure, below the maximum permissible temperature of
427°C for vessel supports& skirts and 550°C for structural steel
members respectively, for a minimum time period of 2 hours. The
material shall not fail till the end of the specified period.
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SPEC. NO.
SHEET 5 OF 6
b) The coating shall be non-corrosive to the steel members & shall not
be affected by environmental conditions, whether natural or from
local leaks, spillage or pollution. It shall also be asbestos free.
c) The coating shall be able to withstand both thermal shock and
impingement of water from fire hoses and/or monitors.
d) The coating material shall be durable and easily repairable.
e) Application procedure of the coating shall be easy, non- hazardous
and also shall not interfere with the working of the adjoining areas.
f) The contractor shall submit calculations of coating thickness for all
structural steel sections to be fire proofed; for review/approval of the
ENGINEER or OWNER for the branded product but in no case
thickness of coating shall be less than 40mm.
6.3.2. Application
a) Vermiculite cementitious coating shall be mixed with water on a clean

platform or in a clean mixing box or in a suitable mixer as per
manufacturer’s specifications. Water cement ratio shall be adjusted
so that vermiculite cementitious coating adheres properly to steel
surface and does not sag or slide upon application.
b) Primer compatible with the vermiculite cement coating as
recommended by the manufacturer's shall be applied over the
steel surface after cleaning the shop primer if required as per the
manufacturer's specifications.
c) Mixed vermiculite cementitious coating shall generally be applied,
over the steel surface, with the help of spray gun except for
small areas and inaccessible location, where application with
conventional hand tools shall be permitted. Mixed vermiculite shall be
used within the pot life specified by the manufacturer. Under no
circumstances rebound material shall be used.
d) The full specified thickness shall be developed in three successive
coats.
- Rendering Coat : Thickness 8 to 12 mm
- Floating Coat : Thickness 12 to 22mm to give total
thickness of 30mm up to the floating
coat
Each successive layer shall only be applied after the preceding layer
has developed its initial set and is also properly scratched with steel
brush to develop proper bond. If the application is interrupted and
does not satisfy successive layers criteria, the coating shall be cut
back to the steel surface/proceeding layer with a trowel at an inclined
angle. Exposed surface of this coating shall be thoroughly wetted
before resuming the work.
e) Application of mixed vermiculite shall not be carried out if the air
temperature or the temperature of the surface to be fire proofed is 4
R0

SPEC. NO.
SHEET 6 OF 6
° C or less. Provision shall be made for adequate ventilation during

and after application, until the coating is dry.
7. FINISHING AND JOINTSEALING
7.1. Fire proof coating shall be finished with 2 coats of micro-porous exterior top
coat, compatible to cement surfaces, of approved make & colour
conforming to IS specifications.
7.2. All exposed joints between fire proofing material coating & steel shall be
sealed with min. 1 Omm thick bitumen mastic flashing, when not otherwise
shielded.
8. TEST
8.1. Tests for shotcrete shall be carried out as specified in M4-403-06.

8.2. Tests for cast in situ concrete M20 shall be as specified in M4-403-01.
8.3. The Contractor shall submit the certificate of test results for the vermiculite
cementituous coating over structural members from a laboratory, approved
by the ENGINEER or OWNER, along with the bids. Test shall be performed
as per the requirements laid down in “UL-1709 – Rapid Rise Fire Tests of
Protection Materials for structural steel”.
9. PAYMENT
9.1. Payment for fire proofing by shorcreting or guniting, shall be made on cubic
metre (m3) basis of actually finished work or as calculated from the
construction drawings, whichever is less.
9.2. Payment of fire proofing using intumescent paint shall be made based on the
square meter (m2) basis of finished surface area or as calculated from the
drawings, whichever is less.
9.3. The rate quoted shall be inclusive of all labour, material, form work, plant &
tools etc. required for the successful and satisfactory completion of work
including curing, curing compound, all cleaning operations before and after
the work, preparation of the surface as specified, applying the primer coat
compatible with the primer already applied over nuts and effected surface of
steel surfaces due to welding , finishing the surface smooth, painting the
surface with 2 coats of micro-porous exterior top coats & sealing the joints
with sealing compounds, providing required access, working platforms,
props, scaffolding and other safety measures including their removal after
completion.
9.4. The rate shall also be inclusive of supplying and fixing of reinforcement with
nuts by using tying wire ( ex c l u di n g the cost of expanded metal steel sheets,
cover plates, which shall be paid extra) and other required accessories for
satisfactory completion of the work as specified and directed.
9.5. The rates quoted shall be inclusive of the tests specified and directed to
establish the quality and strength of materials.
R0

2G BioEthanol-Civil and Structural Works Spec-BPCL-TCE

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2G BIO ETHANOL REFINERY PROJECT

Rev No R0 Date of Issue 26-07-2021

BHARAT PETROLEUM CORPORATION LTD

TECHNICAL SPECIFICATIONS FOR

CIVIL AND STRUCTURAL WORKS

2G Bio Ethanol Refinery Project

Bargarh, Odisha, India

Rev. Date Doc Title:

26-07- EPCM: TATA Consulting Engineers PPB

Rev No R0 Date of Issue 26-07-2021

R0 ISSUED FOR APPROVAL HSP JK PPB 26-07-2021

LEGENDS AND DETAILS:

Initials Name Organisation e-mail

Rev No R0 Date of Issue 26-07-2021

Sr. No. Discipline Details of Change Reason of Change Remarks

SPECIFICATION NO. TCE. 12282A-CV-3000-3001

TECHNICAL SPECIFICATIONS FOR

CIVIL AND STRUCTURAL WORKS

CLIENT : BHARAT PETROLEUM CORPORATION

LOCATION : BARGARH, ODISHA

CONSULTANT : TATA CONSULTING ENGINEERS LIMITED

JOB NO. : TCE 12282A

FILE NAME: TCE.12282A-CV-3000-3001

FILE NAME: F-329-Rev-R7.docx TCE FORM NO. 329 R7

FILE NAME: TCE.12282A-CV-3000-3001

FILE NAME: F-329-Rev-R7.docx TCE FORM NO. 329 R7

F1 SCHEDULE OF DEVIATIONS FROM

D2 TCE.M4-418-01 EARTHWORK IN GRADING, EXCAVATION

D4 TCE.M4-403-01 REINFORCED CONCRETE AND ALLIED

D7 TCE.M4-405-02 R9 ERECTION OF STRUCTURAL STEEL 14

D8 TCE.M4-405-04 SPECIFICATION FOR PAINTING OF

D10 TCE-M4-419-01 R4 GENERAL BUILDING WORKS 174

D11 TCE-M4-419-08 R4 ALUMINIUM FALSE CEILING 6

D12 TCE-M4-419-11 R5 ANTI-TERMITE TREATMENT IN BUILDING 5

D13 TCE-M4-419-12 R5 FALSE OR CAVITY WALL 9

D14 TCE-M4-419-14 R4 SPECIFICATIONS FOR FIREPROOF DOOR 9

WATER SUPPLY, SANITARY & DRAINAGE

FILE NAME: TCE.12282A-CV-3000-3001

FILE NAME: F-329-Rev-R7.docx TCE FORM NO. 329 R7

SPECIFICATION FOR SHOT CRETING

NOTE 1: SECTION D IS GENERAL TECHNICAL SPECIFICATION CONSISTING OF MANY

NOTE 2: ANNEXURE 1 IS AN EXHAUSTIVE LIST OF VENDORS. CONTRACTOR TO CONSIDER

NOTE 3: IN CASE OF PREFERENCES OF SPECIFICATIONS SELECTION,

FILE NAME: TCE.12282A-CV-3000-3001

FILE NAME: F-329-Rev-R7.docx TCE FORM NO. 329 R7

Bharat Petroleum Corporation Limited (BPCL) is a Government of India

2.0 ABOUT SITE

The Site is divided in two parts comprising of an area of approximately

3.0 SCOPE OF WORK

Table 1 - List of Major buildings / facilities / structures

SR.NO STRUCTURES / EQUIPMENT

1. General Civil Works

FILE NAME: F-329-Rev-R7.docx TCE FORM NO. 329 R7

3. Technological Structures & Piperacks

FILE NAME: TCE.12282A-CV-3000-3001-01

FILE NAME: F-329-Rev-R7.docx TCE FORM NO. 329 R7

BHARAT PETROLEUM CORPORATION

TATA Consulting Engineer Limited,

PACKAGE II – CIVIL, STRUCTURAL

4. Location Bargarh, Odisha

Nearest City Jharsuguda

5. Site elevation 3.00 M above MSL

6.0 Transport Road & Railway

Nearest Railway Station Bargarh