MSS-METHOD STATEMENTS Mitendra

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PROJECT NAME: MV SUBSTATION - 33KV MILLING
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NAME OF CLIENT: KAMOA COPPER S.A.
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METHOD STATEMENTS
Responsible Person Signature Date
MSS PROJECT MANAGER
MSS QA/QC CO-ORDINATER
DRA SITE CIVIL SUPERVISOR
DRA QA/QC CO-ORDINATER
KCSA SHE MANAGER
Use Standard Flow Chart Symbols in Process approach Flowchart:
Start/End Process Flow Process Alternate Document Information/Data

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Property of MES – Approved (Controlled document in Document Repository)

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INDEX
SR.N PAGE
DESCRIPTION
O NOS.
0. COVER PAGE 1 001 - 001
0. INDEX 002 - 002
1. HEALTH, SAFETY & ENVIRONMENTAL 003 - 004
2. METHOD STATEMENT FOR SURVEYING WORK 005 - 006
3. METHOD STATEMENT FOR EXCAVATION AND BACK FILLING 007 - 013
4. METHOD STATEMENT FOR RCC WORK - (SHUTTERING, REINFORCEMENT & CONCRETING WORKS) 014 - 060
5. METHOD STATEMENT FOR MASONRY WORKS 061 - 072
6. METHOD STATEMENT FOR INTERNAL PLASTERING WORK 073 - 078
7. METHOD STATEMENT FOR EXTERNAL PLASTERING WORK 079 - 085
8. METHOD STATEMENT FOR FALSE CEILING GYPSUM WORK 086 - 089
9. METHOD STATEMENT FOR INTERNAL PAINTNG WORK 090 - 094
10. METHOD STATEMENT FOR EXTERNAL PAINTNG WORK 095 -099
11. METHOD STATEMENT FOR TILING, SKIRTING, TOILET DADO & PLATFORM WORK 100 - 109
12. METHOD STATEMENT FOR DOORS & FRAMES AND WINDOW FRAMES 110 - 116
13. METHOD STATEMENT FOR ROOFING SHEETING 117 - 121
14. METHOD STATEMENT FOR PLUMBING AND DRAINAGE WORK 122 - 138
15. METHOD STATEMENT FOR CONDUTING 139 - 143
16. METHOD STATEMENT FOR FABRICATION & INSTALLATION WORK 144 - 157
17. METHOD STATEMENT FOR WATERPROOFING WORK 158 - 174
18. APPLICATION PROCEDURE FOR NON- SHRINK GROUT FOR STRUCTURAL 175 - 180
19. METHOD STATEMENT FOR DOOR FRAMES & SHUTTERS 181 - 186
20. METHOD STATEMENT FOR SANITARY WARES, FITTINGS & ACCESSORIES INSTALLATION 187 - 190
22. METHOD STATEMENT FOR EPOXY RESIN COATING WORKS FOR FLOOR 191 - 198
END PAGE 199

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GENERAL NOTE FOR
HEALTH SAFETY & ENVIRONMENTAL

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HEALTH SAFETY & ENVIRONMENTAL
1. Health & Safety

 All employees will wear PPE. This includes Safety harness, overalls, safety boots and/or
gumboots with spats, hardhats, gloves, safety glasses and ear protection.
 Employees to have completed working at heights training.
 Employees to be hook up at all times.
 All plant will be inspected on arrival on site for safety and environmental compliance and a
permit will be issued.
 All plant will be checked daily and records filed with KCSA Safety Department.
 All activities will be covered by individual risk assessment and safe work procedure which will be
presented to the labour carrying out the activity in DSTI’s and toolbox talks.

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 All scaffolding to be erected and dismantled as per KCSA Safety Plan.
 All scaffolding to be erected by trained and appointed scaffold erectors.
 All scaffolding to be inspected by trained and appointed scaffold inspector.
2. Environmental
 Hazardous substances will be stored on site as indicated in the Environmental Method
Statement on the Handling, Storage and Management of Hazardous Substances. MSDS will be
available for appropriate chemicals/fuels stored.
 All waste materials will be disposed of as indicated in the Environmental Method Statement on
Waste Management
 Toilet and hand wash facilities will be supplied by KCSA as indicated in the Environmental
Method Statement on Site Establishment.
3. Records: Records will be recorded / submitted as per approved KCSA Quality Assurance plan.

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METHOD STATEMENT
FOR
SURVEYING WORK
SURVEYING WORK
1. Scope:
The scope includes the guidelines to be adopted for setting out and surveying works.
2. Reference Documents:
- BOQ / CONTRACT TENDER DOCUMENT
3. Equipment’s:

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Calibrated auto-level, total station / theodolite and other appropriate survey equipment’s and
accessories.
4. Procedure:
1. Prior to use, ensure that all survey equipment’s (including hire equipment’s) have valid
calibration certificates.
2. Take over base co-ordinates furnished by clients / consultants and set up bench mark
datum.
3. Establish 2 station points (having specific Northing and Easting) at accessible locations
away from periphery of the building to be constructed. Ensure that bench mark shall
remain undisturbed till the completion of project.
4. Construct masonry pillars for the established permanent bench marks with embedded
steel plates at top. Plaster and finish the top surface neatly.
5. Drive 20 mm dia. rebar’s to at least 1.50 m depth all around the pillars and barricade the
pillars so as to protect he pillars from displacement.
6. Recheck the benchmark co-ordinates and put paint, punch marks on top.
7. Establish control pillars for individual structures as above with reference to benchmarks.
8. Run the traverse on all sides of structure and establish set out stations on grid lines.
9. Mark grid lines with reference to temporary benchmarks in both X and Y direction with
paint.
10. Plot detail survey plan showing site boundary, all reference points / pillar locations in
Auto-cad.
11. Superimpose building points given in architectural points over the plotted survey plan.
12. Refer this auto-cad drawing transfer centre line and out-lines points of walls, columns and
footings on the PCC.
13. Also transfer reduced levels from temporary bench mark for such at raft top, footing, tie-
beams etc.
5. Records :
1. Joint measurement and records surveying and levelling works.
2. Any other records as per contract requirements.
6. Reference Documents :
7. ITP Reference No :

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METHOD STATEMENT
FOR
EXCAVATION & BACK FILLING

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EXCAVATION AND BACKFILLING

Raw Materials Used, Inspection and Acceptance Criteria
A) Materials used for backfilling:

1) Soil:
Soil for backfilling shall be freshly excavated, free from vegetation, boulders, silt and clay. Soil can
be either hard or soft.
NOTES:
1) All backfill material other than rubble shall be free from roots, grass and rubbish. It shall be
reasonably well graded and of maximum size 80 mm. All lumps and clods of size larger than 80
mm shall be broken down using wooden mallet.
2) Material brought from outside sources shall be approved by Quality Engineer at the place of
source and shall be visually checked each time during its delivery and unloading at site throughout
the period of backfilling work.
3) Backfill material shall be tested in laboratory at time of approval from source.
4) Change in source of materials shall be avoided. If unavoidable, the new sample and the source
shall be again approved by Quality Engineer before actual commencement of supply of materials
at site from fresh sources.
5) All backfill material shall be tested in laboratory once at the time of approval from source.
B) Water:
By mere observation, water should be clean and free from dirt and organic matter. Waste (treated)
water from STP can be considered suitable for compaction of backfill material.
Guidelines for Inspection of Backfill Material:

(Testing shall be done in laboratory only once at the time of approval of source)
Sr. No Description Mode of Inspection Acceptance Criteria
A Murum
1 Field Density Lab Test Not less than 90% of Max Dry Density

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2 Plasticity Index Lab Test Not greater than 10

Standard Proctor Density
As per SANS
3 or Lab Test
Modified Proctor Density
4 Maximum Dry Density Lab Test As per lab test
5 OMC Lab Test As per lab test
E) Storage of Raw Material:

a) Soil for backfilling:
1) Excavated materials which in the opinion of Client and contractor are useful shall be stacked in
regular heaps, bunds with regular slopes. Such stacking shall be done within the lead (50 m or as
specified).
2) Stacks of soil shall be properly levelled for providing natural drainage.
3) All softer material shall be laid along the centre of heaps. The harder and more weather-resisting
materials shall be stacked so as to form the casing on the sides and the top of heaps of softer
material.
4) Soft and hard rock shall be stacked separately.
5) Murum, Sand and Rubble brought from outside shall be stacked separately in regular heaps of
height not more than 1.5m. Stacking shall be done as near to the place of filling as possible to
avoid excess lead. Berm width shall not be less than 0.8m.
6) For borrowed material, stacking shall be done truck-load wise all along the edge of excavated pits.
Material shall not be stacked against an existing wall.
7) Toe boards shall be provided to prevent stacked material from falling back into the excavated pits
F) Equipment and Tools:

a) Excavation and backfilling Equipment’s:
 JCB
 Pokhlain
 Jack hammers
 Dumpers
 Concrete cutter (If required)
 Surface compactor

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 Tandom roller
 Vibratory roller
 Dewatering pumps of suitable capacity
 Pressure pump for spraying anti-termite treatment solution
 Screeder
 Vibratory Roller
b) Surveying Equipment’s:
 Theodolite
 Whole station equipment
 Auto level
 Levelling staff
 Spirit Level
 Right Angles
 Paint & Brushes
c) Tools:
 Crowbars
 Pick axes
 Spades
 Wedges
 Hammer
 Line Dori (50m)
 Measuring tape (50m)
d) Temporary Facilities:
 Platforms
 Walkways
 Shoring and strutting material (if required)
 Night lamps
 Procedures for Excavation and Backfilling works

Pre-Excavation Procedures:
Setting out:

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1) It shall be ensured that drawing indicating setting out points is available on site. Also necessary
surveying equipment as mentioned shall be available on site in good operational condition.
2) Setting out work shall be carried out using Theodolite or whole station Instrument. Setting out
of centre lines shall be done correctly as per drawing and masonry or concrete pillars shall be
erected at suitable points to serve as reference bench marks (or setting of wooden railings
around periphery of the building). Levels of reference bench marks shall be with respect to a
Permanent Bench Mark, which shall be made to draw excavation profile. All marking on these
shall be painted red and well preserved.
3) All excavation levels shall be determined from the reference bench marks and got approved
from Client before actual excavation work starts.
4) Client shall check and approve in writing the entire setting out profile, before which no
excavation work shall commence.
Excavation:
1) It shall be ensured that all necessary equipment, tools, instruments, material and consumables
including temporary facilities like platform, walkways etc. as mentioned are available at site.
2) All skilled / unskilled manpower along with supervisory personnel for carrying out work shall
have sufficient experience on similar works.
3) Excavation drawings shall clearly indicate in plan (preferably by dotted line) the part of soil to
be excavated and also levels to which excavation needs to be carried out.
4) For the purpose of understanding terminology used for soil to be excavated, soil shall be
classified in accordance with SANS code as under:
a) Ordinary soils:
These shall include all kinds of soils containing sand, silt, hard and soft laterite, shingles, gravel, clay,
loam, ash, etc. which can generally be excavated by spades, pick axes and shovels.
Removal of the same shall be done by mechanical excavators, shovels, draglines etc.
b) Soft and Decomposed rock:

This shall include rock, boulders, chalk, slate, laterite and all other materials which does not need
blasting and can be removed with picks, hammers, crow bars, wedges and pneumatic breaking
equipment like Jack Hammers.

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c) Hard Rock:
This shall include all rock, occurring in large continuous masses, which cannot be removed except by
blasting. Boulders of rock occurring in such sizes and not classified under (a) and (b) above shall also
be classified as hard rock. Excavation in reinforced cement Concrete Works shall be treated as
excavation in hard rock.
During Excavation Procedures:
1) The excavation shall be done to correct lines, dimensions and levels as per drawing. Adequate
side slopes shall be maintained during excavation of loose soil to prevent soil from sides of
excavated pits from falling back into the pits.
2) Wherever required, proper shoring and strutting shall be provided to maintain and prevent sides
of excavations from collapsing.
3) No heavy equipment shall be allowed within 4m from edge of excavation or within a distance
equal to depth of excavation, whichever is less.
4) Excavated materials shall not be deposited within 1.5 m from edge of the excavation.
5) Any material obtained from the excavation which in the opinion of the Site Engineer is useful,
shall be stacked separately in regular stacks as directed by client / contractor engineer. Any
excavated material, which is not suitable for backfilling shall be carted away from the work place
as per directions of Site Engineer.
6) Planks placed over trenches for crossing shall not be slippery and of width not less than 75 mm
wide.
7) Necessary barricades shall be erected and maintained around excavated areas. Also warning
lamps at
Night shall be provided to ensure safety.
8) Pits shall not be excavated to final founding level, if concreting work is not to be carried out
immediately. Last 15 cm shall be excavated prior to providing blinding layer with lean concrete
(PCC). PCC shall be of proportion 1:2:4 or as specified by consultant.
9) If by mistake, excavation is carried out below the level mentioned on the drawing, the same shall
be made up to correct level by filling with concrete.
10) If any bottom of excavation is left exposed and is deleteriously affected by atmosphere or water,
it shall be dewatered and excavated to sound base. Base of excavation shall then be filled up to
the required level with lean concrete. (Grade M-15 or as specified by consultant)
11) Removal of buried piping, cables or any other underground services shall not be done without
prior permission of Client and all measures shall be taken to protect such lines till their removal.

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12) Adequate precautions as per Consultant’s advice shall be taken to ensure that the excavation
operations do not damage the adjoining structures or dislocate underground services.
13) Any trees coming in the alignment of the excavation shall be cut after obtaining prior approval of
concerned authorities and any specific requirement laid out by them shall be complied with. Cut
trees shall then be removed from site as per instruction of Site Engineer.
14) Roots of trees not coming in the portion of excavation pits but whose removal is essential shall
be removed and hollows shall be filled up during backfilling.
15) Suitable drainage arrangements shall be provided to prevent surface water entering excavated
pits. Water within the pits shall be bailed out or dewatering shall be carried out using pumps of
adequate capacity to keep excavations free of water. Water removed shall be disposed off, away
from the excavated area.
16) Where water table is high, lowering of water table shall be carried out by well point system so
that general water table is below excavation level.
17) Excavation in rock shall be carried out either by chiselling with pneumatic drills or by blasting.
Chiselling shall be carried out to obtain correct slopes, shape and pattern of excavation pits as
per drawings.
18) Depth, dimension and levels of excavated pits shall be approved and recorded by the client /
contractor Site Engineer in the field book with signature of concern persons. Nature of the soil
at the excavated pit bottom shall be examined by client Engineer. If there is doubt regarding
safe bearing capacity (SBC) of soil, Consultant’s opinion shall be taken and appropriate test shall
be carried out to determine safe bearing capacity of soil. Further excavation shall be carried out
in such cases, if the consultant advice to do so.
19) After approval from client, bed of the excavated pits shall be firmly consolidated and levelled by
watering and mechanized compacting. Compaction shall be carried out using surface vibrators in
case of small pits and by roller if the area is large. Defective spot shall be dug and filled with
concrete.
20) Concrete foundation work shall start only after Site Engineer gives the permission to do so in
writing. Laying plain cement concrete shall be carried out after the compaction of sub base has
been carried out to the satisfaction of Site Engineer. However, it shall be ensured that base is in
moist condition before laying PCC. If necessary, base shall be saturated with water for not less
than 6 hrs. But not exceeding 20Hrs.
Backfilling:

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1) Backfilling work shall not start until client gives his approval to do so. Material used for backfilling
shall be any one or combination of soil types mentioned
2) Back filling shall be done in layers of thickness not exceeding 30 to 45cm depending on compaction
equipment and method (loose soil before compaction). The soil layer shall then be watered
adequately and compacted to minimum 90% to 95% of Standard Proctor Density for soil other
than sand and 85% in case of sand. Compaction shall be carried out at optimum moisture content
(OMC). Soil after compaction shall be free from pockets underneath.
3) After the compaction of final layer of soil, at least 3 cores shall be taken from the areas directed by
Site Engineer and the soil shall be tested in laboratory for the degree of compaction achieved.
Results shall be matched above.
4) If the soil is excessively wet, it shall be allowed to dry sufficiently before compaction.
(Approximately OMC should be maintained)
5) Compaction shall be done with suitable mechanical equipment such as plate vibrator, vibratory or
tendon roller, or 10 Tonnes Power Roller as suitable for the area to be compacted. In areas where
mechanized compaction cannot be done, hand compaction shall be resorted to as directed by the
Site Engineer. Overall compacted thickness of soil shall be as per drawing.
6) Over the compacted ground, rubble soling shall be done. Stones shall be hand packed as close as
possible and bedded firmly on broadest base. Void shall be filled with chips and small stones.
7) Backfilling around water retaining structures shall be done only after testing of structures against
leakage is done.
Records :
Reference Documents :
ITP Reference No :

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METHOD STATEMENT FOR

RCC WORK (SCAFFOLDING DESIGN,
SHUTTERING, REINFORCEMENT &
CONCRETING WORKS

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RCC WORK
RCC work can be divided into 3 parts:
 Reinforcement Steel
 Formwork
 Procedures for Concreting
 Reinforcement Steel
Scope
The requirement of deformed steel bars and wires for use as reinforcement in concrete is basically
categorized in the following three strengths.
 Fe 415
 Fe 500
 Fe 550
Steel reinforcement and its requirement in concrete structure:
Steel reinforcements are used, generally, in the form of bars of circular cross section in concrete
structure. They are like a skeleton in human body. Plain concrete without steel or any other
reinforcement is strong in compression but weak in tension. Steel is one of the best forms of
reinforcements, to take care of those stresses and to strengthen concrete to bear all kinds of loads.
Bar-bending-schedule:
Bar-bending-schedule is the schedule of reinforcement bars prepared in advance before cutting and
bending of rebar. This schedule contains all details of size, shape and dimension of rebar to be cut.
Types of steel reinforcements used in a reinforced concrete structure:

Mild steel bars conforming to SANS and Cold-worked steel high strength deformed bars conforming to
SANS (grade Fe 415, grade Fe 500 and Fe 550, where 415, 500 and 550 indicate yield stresses or 0.2 %
proof stress in N/mm2) are commonly used. Grade Fe 415 is being used most commonly nowadays. This
has limited the use of plain mild steel bars because of higher yield stress and bond strength resulting in
saving of steel quantity. Some companies have brought thermos mechanically treated (TMT) and
corrosion resistant steel (CRS) bars with added features. Bars/wires range in diameter from 4 to 50 mm.

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Cold-worked steel high strength deformed bars start from 8 mm diameter. For general house
constructions, bars of diameter 6 to 20 mm are used.
Specifications:
The reinforcement steel is generally available in three forms.
1) Mild steel rounded bars of different grades
2) High strength deformed of different grades and types
3) Corrosion Resistant Steel
The structural requirements of reinforcing steel:
Reinforcing Steel has to satisfy some basic requirements to efficiently perform in concrete structures.
Durability of the reinforced concrete structures will greatly depend on the basic requirements. A few of
them are as given below:
 Tensile strength
 Bond strength
 Ductility
 Bendability
 Weldability
 Fatigue strength
 Corrosion resistance
 Fire resistance
Terminology:
 Batch:
Any quantity of bars /wires of same size and grade whether in coils or bundles presented for
examination and test at one time.
 Bundle:
Two or more coils or a number of lengths properly bound together.
 Elongation:
The increase in length of a tensile test piece under stress. The elongation at fracture is
conventionally expressed as a percentage of the original gauge length of a standard test piece.
 Longitudinal Rib:
A rib of uniform cross-section, parallel to the axis of the bar/wire (before cold-working, if any).
 Nominal Diameter or Size:
The diameter of a plain round bar / wires having the same mass per metre length as the deformed
bar / wire. Nominal Perimeter of a Deformed Bar / Wire - 3.14 times the nominal diameter.

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 Nominal Mass:
The mass of the bar / wire of nominal diameter and of density 0.00785 kg/mm2 per metre run.
 0.2 Percent Proof Stress:
The stress at which a non-proportional elongation equal to 0.2 percent of the original gauge length
takes place.
 Tensile Strength:
The maximum load reached in a tensile test divided by the effective cross-sectional area of the
gauge length portion of the test piece. Also termed as ultimate tensile stress.
 Transverse Rib:
Any rib on the surface of a bar / wire other than a longitudinal rib.
 Yield Stress:
Stress (that is, load per unit cross-sectional area) at which elongation first occurs in the test piece
without increasing the load during tensile test. In the case of steels with no such definite yield point,
proof stress shall be applicable
Table No. 1
Typical properties of Thermax Rebars N/mm 2 as compared to the minimum requirements specified in
the various codes:
Properties Fe415) Thermax Fe500 Thermax Grade 460 Thermax

400 500 B.S.4449 450
Yield strength 415 430 - 480 500 520-580 460 460

Min. N/m2
U.T.S Min. 485 500 - 590 545 590-660 506 520
N/mm2
A5 elongation 14.5 19 – 25 12 18 - 24 12 17
min %
Stress ratio min 1.10 1.15 – 1.25 1.08 1.15 – 1.05 – 1.10 1.12
yield 1.25
strength/ultimate
tensile strength
Carbon < 0.30 < 0.25 < 0.30 < 0.25 < 0.25 < 0.25

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NOTES:
 Thermax Thermo-Mechanical Treatment (T.M.T) bars produced by adopting quenching and
tempering patented technology are far superior for high performance RCC structures.
 The tendency of pit propagation in T.M.T. 42 C.R.S. bars is comparatively less than high strength bars
produced without using alloying elements while rolling. Pit propagation is also observed to be more
on cold twisted deformed bars than T.M.T. 42 C.R.S. bars.
 It is observed that T.M.T. 42 C.R.S bars have a competitive edge over other rebar where corrosion
resistance is concerned.
Table No. 2
Physical Properties of Reinforcement steel as required by various standards:
Property Normal size of bar SANS

Fe415 Fe500 Fe550
Min. Ultimate tensile All sizes 10 % more than yield 8 % more than yield 6 % more than
strength (MPa) stress, min. 485 stress, min. 545 yield stress, min.
585
Min. Yield stress Up to 20 mm 415 500 550
(MPa) 20 to 40 mm 415 500 550
Min. Elongation (%) All sizes 14.50 12.00 8.00
Mandrel dia. For Bend Up to 22 mm 3d 4d 5d
Test Above 22 mm 4d 5d 6d
No cracks should be No cracks should be No cracks should
observed observed be observed
Mandrel dia. For Up to 10 mm 5d 5d 7d
ReBend Test Above 10 mm 7d 7d 8d
No cracks should be No cracks should be No cracks should
observed observed be observed
Table No. 3
Chemical properties of Reinforcement steel as per various standards:
Property (% -Max) SANS CRS

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Fe 415 Fe 500 Fe 550

Carbon 0.300 0.300 0.300 0.18
Sulphur 0.060 0.055 0.055 0.05
Phosphorous 0.060 0.055 0.050 0.12
Sulphur + 0.110 0.105 0.100 0.17
Phosphorous
Silicon --- --- --- 0.45
Manganese --- --- --- ---
Corrosion --- --- --- 1.50
Resistant Elements
Procedure:
1) Material received at site should have ISI / ISO certification mark or the supplier should be pre -
approved from QA department after verification of physical and chemical properties as specified in IS
1786. Bars should be marked to identify categories.
2) For diameter up to 12 mm, one sample per diameter per supplier/manufacturer for every 60 Ton
must be tested in an independent/external laboratory. For diameter above 12 mm, one sample per
diameter per supplier/manufacturer for every 100 Ton must be tested in an independent/external
laboratory.
3) Proper equipment / jig should be available for straightening the coiled steel and mandrel for bending
and cutter machine for cutting steel bars.
4) Use of latest revisions of drawings and bar bending schedules should be done.
5) Bent bars of identical size, shape and type must be bundled together and labelled correctly before
placing.
6) Steel surface should be free from grease, oil, mud, mould oil, loose mill scales, excessive rust scales,
and loose concrete.
7) Binding wires must be bent inwards or loose ends cut so that they do not come in cover zone and/or
protrude out of concrete.
8) Beam-column junctions reinforcement steel bars should bunch or spaced properly to avoid
congestion.
9) Enough space between bars should be available to place and compact concrete.

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10) Radius of bend given to dowel at construction joints must be as per drawing or as specified by
structural consultant.
11) For long duration of storage, bar must be protected by corrosion resistant passivator / converter
coat.
12) Bars of different types and diameters must be stored separately and clear identification between
tested and untested steel should be marked at site.
13) Reinforcement bars received at site should be stored on hard concreted platform and clear above
the ground with the use of timber sleeper, concrete sleeper or any other means. Reinforcement should
be kept covered by tarpaulins or plastic sheets to avoid excessive corrosion and other contamination.
14) Cover blocks should be of non-corrosive material such as plastic or concrete/mortar but not wooden
or broken tile, broken bricks or stone. Especially PVC made cover spacers should be used in the works.
15) Binding wire should be 16 or 18 gauge conforming to SANS. It should be free from rust, oil, paint,
grease or any other deleterious material.
16) Splices should be provided as far as possible away from sections of maximum stress and must be
staggered.
17) Where more than one-half of the bars are spliced at a section or where splices are made at points of
maximum stress, special precaution should be taken, such as increasing the length of lap and / or using
spirals or closely spaced stirrup around the length of the splice. (Staggered laps) or as suggested by
structural consultant.
18) Horizontal distance between two parallel main reinforcing bars shall usually not less than the
greatest of the following:
 The diameter of the bar if the diameters are equal,
 The diameter of the larger bar if the diameters are unequal, and
 5 mm more than the nominal maximum size of coarse aggregate.
19) Greater horizontal distance than the minimum specified in Clause no. 18 should be provided
wherever possible. However, when needle vibrators are used, the horizontal distance between bars of a
group may be reduced to two-thirds the nominal maximum size of the coarse aggregate, provided that
sufficient space is left between groups of bars to enable the vibrator to be immersed.
20) Where there are two or more rows of bars, the bars shall be vertically in line and the minimum
vertical distance between the bars shall be 15 mm, two-thirds the nominal maximum size of aggregate
or the maximum size of bars, whichever is greater.
Tests to be carried out on Reinforced steel

A) Physical Tests

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 Rolling Margin
 Tensile Test: - 0.2% proof stress, yield stress, elongation etc.
 Bend and rebend test.
B) Chemical Tests.
 Carbon
 Sulphur
 Phosphorous
 Sulphur + Phosphorous
 Silicon
 Manganese
 Corrosion Resistant elements
Checklist before accepting consignment of steel:
Following check points should be considered before accepting the consignment of steel.
1) The type of steel i.e., mild steel/high strength deformed or twisted/corrosion resistant steel.
2) The grade of steel based on chemical and physical requirement.
3) The rolling margin.
4) The original steel certificate issued by steel supplier.
5) The physical and chemical properties in manufacturer’s test certificate.
6) Bend Rebend test at site.
Following check points should be checked after placing of steel:

1) The cutting and bending are in order.
2) Spacing between bars as per drawing
3) The effective depths, top and bottom cover in slab as per drawing.
4) Position of top steel bars in case of cantilever slabs.
5) Corrosion inhibiting layer applied over the steel bars if specified.
6) The lap length and hook length / angle of bars as per drawing.
7) The welding of bars as per drawing or as per standard details.
8) Deviation due to any reason is verified by design office.
 Formwork
General:

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Formwork is dye or mould used to shape the wet concrete until it sets and attains sufficient strength to
carry its own weight and retains its shape. There are various types of shuttering material used for
construction in India. Some of them are given below:
 Conventional shuttering system

Formwork and False work (F& F)—Terminology:
 Formwork (Shuttering):
Mould to contain the wet concrete in the desired shape.
 False work (staging, cantering):
Temporary structure used to support a permanent structure during erection and until it becomes
self-supporting.
 Scaffolding (Paranja):
Light structural “Framework” for easy access of workmen.
 Striking (Stripping):
Scientific dismantling and removing formwork (pre-planned).
 Sheeting (Sheathing):
Supporting membrane in contact with the wet concrete.
 Joist (Batten):
Horizontal member supporting sheeting (slabs & beams).
 Bearer (Runner):
Horizontal member supporting joists.
 Prop cap:
Seating for bearer. (Axial load)
 Prop:
Vertical member supporting bearer
 Prop base:
Seating for prop (Punching shear).
 Prop footing (Spreader)
Member transferring all loads on unyielding strata.
 Wedge:
Packing piece used for correct levelling & easy striking of formwork.
 Wailing or Waling:
Horizontal member resisting hydrostatic concrete load on sheeting (vertical walls)
 Stud:

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Vertical member resisting hydrostatic concrete loads on sheeting. (Walls).

 Soldier:
Vertical supporting member cantilevered from previous concrete.
 Yoke:
a) For columns - Horizontal frame support encircling formwork.
b) For slip form - Vertical frame support straddling inner & outer formwork.
 Stop-end (Bulkhead):
Vertical formwork to form a construction joint in concrete.
 Back form:
Formwork to the top surface of a sloping slab
 Bracings:
a) Horizontal - Member in 2 direction slenderness ratios of props.
b) Diagonal - Member transferring horizontal and wind loads through props.
 Tie Bolt:
Interconnecting two opposite formworks to resist hydrostatic loads.
 Riband:
Horizontal member laid flat to resist horizontal pressure from formwork.
 Starter (Kicker):
Small height of wall or column cast along with the footing.
 Shikanjas:
To hold the 2 opposite formwork or to hold the two right angle formworks.
 Four-way head:
To support to I-section beams below slab or beam bottom.
 Tripod:
To keep prop in exact plumb & position.
Conventional Shuttering System:
Specification:
Following are the materials used for formwork shuttering work.
1) Props
 Timber props
 Adjustable Telescopic Steel Props
Timber Props:
 Timber props shall be used only where height of structure is less than 2.4 meter

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 Timber props shall have uniform cross section throughout their length and shall be free of cracks,
bends, splits, and knots and warping. Any part of prop should not show signs of decay. Top and
bottom ends shall be sawed to true horizontal plane. Props with outer skin showing peeling and
rotting shall be rejected.
 Cracks if present shall be restricted to 1.5mm in width, superficial not more than 1/3rd length of
prop and should not propagate till either end. Deviation from plumb, if any, shall be restricted to
L/300.
 Comparatively smaller end of prop should be used as prop head.
 Diameter of wooden prop should not be less than 75 mm.
Adjustable Telescopic Steel Props:

 Steel props shall be telescopic and adjustable type. Diameter of outside and inside tube and weight
shall be as per manufacturer’s literature.
 Generally outer prop is 50 NB (OD 60.3 mm) and inner prop is 40 NB (OD 48.3 mm) of 8 SWG (4mm
thick).
 Outer prop shall be provided with a base plate of size 150 x 150 x 5 mm whereas inner prop may be
provided with top plate / fork head / U head.
 Props shall be truly vertical with the maximum deviation in plumb as 1 in 600.
 There should be minimum 6 threads above and below the sleeve. Prop nut shall be provided to
outer prop in such a way that it can be easily rotated through full height of sleeve. Locking pin (shear
pin) shall be of high tensile steel and of minimum 12mm diameter.
 In addition to above props, some mini props (junior props) for supporting concrete members at
short heights shall also be procured as per the requirements.
 Props must be braced in both the directions by tubes and double couplers at approximately 250 mm
above prop nuts when extended beyond 3.6 meters.
Load Carrying Capacity of props:
Long Props:
Height Self-Axial Load
Prop
Closed Extended Closed Extended
0N 1.10 m 1.75 m 3500 kgs 3000 kgs
1N 1.50 m 2.75 m 3200 kgs 2300 kgs
2N 2.00 m 3.25 m 3000 kgs 2200 kgs
3N 2.00 m 3.75 m 2900 kgs 2000 kgs
4N 3.00 m 4.65 m 2300 kgs 1150 kgs

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Mini Props (Junior Prop / light Duty Prop)

 Outer diameter: 50.8 mm
 Inner diameter: 42.2 mm
Height Self-Axial Load

Closed Extended Closed Extended
2.00 m 3.20 m 1500 kgs 1000 kgs
2) Bracings and couplers for steel props:
Bracing pipe for props shall be generally 40 NB (OD 48.3 mm) tubes. Tubes shall be checked for
straightness. All couplers shall be checked at random for proper fitting over the pipes. They shall be
preferably galvanized. Tightening as well as removal shall be easy.
 Adjustable Telescopic Steel Spans:

Steel spans shall be telescopic with inner and outer sections. Manufactured out of sheet, lattices of
10mm diameter bar, main bar 14mm diameter, bearing angle 75 x 75 x 10 mm, with 2 nos. of eye bolts
with additional angle stiffener welded to the sheet and bearing angle from inside.
Total load Permissible clear span for centre line spacing (in mm)
including 180
Slab 300 mm 450 mm 600 mm 800 mm 900 mm 1150 mm
kg/sq. for
Thickness spacing spacing spacing spacing spacing spacing
shuttering &
live load Kg/sq.
100 420 8050 6550 5690 5000 4650 4010
115 456 7800 6400 5510 4750 4470 3890
125 480 7570 6200 5330 4650 4340 3760
140 516 7310 5970 5160 4500 4190 3630
150 540 7110 5790 5000 4350 4090 3560
165 576 6880 5660 4870 4250 3960 3430
180 612 6730 5490 4750 4100 3890 3350
190 636 6550 5360 4620 4050 3780 3280

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200 600 6400 5230 4520 3950 3680 3200

225 720 6150 5000 4340 3800 3530 3070
250 780 5920 4830 4140 3650 3380 2840
275 840 5660 4650 4010 3500 3280 2640
300 900 5490 4490 3730 3400 3150 2490
The Acrow spans should be used preferably for slabs only along the shorter span. Minimum overlap
between the trusses of the Acrow span should be 450 to 600mm with shear pin or packing. (Packing
should be preferably of M. S only) Acrow spans should not be used below beam bottom, staircase, and
waist slab and slopping roof / slab. Acrow span are to be checked thoroughly for their welding and
strength at both the end joints
 H-Frame:
a) H-frame shall be provided when supporting height is beyond the range of opened length of steel
prop.
b) Vertical member of H-frame shall be of 40 NB (OD 48.3 mm) tube whereas horizontal member shall
be 32 NB (OD 42.4 mm) tubes. Bracings shall be 25 NB (OD 33.7 mm) tubes with ends pressed.
c) Vertical members shall be truly vertical and horizontal members shall be truly horizontal. Bracing
tubes shall be easy to fit and remove.
d) Bracing should be fixed with the H Frame with MS locking pins or MS Nails. Tying with coir or binding
wire is not permitted.
 Scaffolding and its components:

a) Steel scaffold tubes shall be generally be of 40 NB (OD 48.3 mm) tubes. Scaffold tubes to be used as
initial standards shall be provided with base plates of size 150 x 150 x 5 mm thk. Base plate shall be
provided with two diagonally opposite holes. Weight of scaffold shall be as per manufacturer’s
specifications.
b) All fittings like swivel, right angle couplers, cup lock, wedge lock, brackets etc shall be galvanized and
painted.

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c) Planks shall be minimum 40mm thick and 300 mm wide and without cracks. Length shall be sufficient
to have at least 300 mm overlaps over adjacent standards / ledgers.
 Cup lock:
Cup lock is a system to connect four horizontal scaffold tubes. Four horizontals rest on a single vertical
prop. These four horizontals are covered with single cup like arrangement at the bottom of Cup lock.
Top of Cup lock is forming a cone at top to hold another vertical prop over it.
Note: - All steel formwork components including scaffolding tubes and fittings are manufactured in
accordance with SANS.
Formwork Materials:
Specifications, Periodic Inspection, design and Detailing
(Unless otherwise specified the material shall confirm to following standards)
1) Slab:
A) Sheathing
 Ply: 12 mm thick marine ply with ISI mark
 MS Plates: Size – 600 x 900 mm or 600 x 1250 mm.
Thickness of plate – 14 G to 16 G
Angle support for plates – ISA 35 x 35 x 5 mm / 30 x 30 x 3 mm / 25 x 25 x 3 mm
B) Sheathing Support (Primary)

 Wooden Runners: 75 mm x 37.5 mm or 75 mm x 50 mm
C) Sheathing Support (Secondary)

 Steel Spans: Supporting angle section – ISA 50 x 50 x 5 mm
Diameter of lacing MS bar – 10 mm dia
 Wooden Runners: 75 x 50 mm
 ISMC: Size as per design
D) Scaffolding
 Steel Props: Outer diameter- 60.3 mm
Top plate – 75 x75 5 mm

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Bottom plate – 150 x150 x6 mm

Pipe specification: IS: 2062 / IS: 8500 / IS: 1161
 Wooden Props : 75 mm dia to 100 mm dia. (wooden props shall be used only where height of
structure
is less than 2.4 meter)
2) Beams:
 Beams Bottom: Wooden planks of 25 mm thick& ply of 12 mm thick Marine ply of ISI mark.
 Beam sides: 12 mm thick marine ply of ISI mark
Beam side horizontal runners – 75 x 37.5 or 75 x 50 mm
Beam side vertical supports – 75 x 50 mm
Beam side inclined struts – 75 mm x 50 mm or 75 mm x 75 mm
 Tie bolts: 16 mm dia
3) Columns:
 Column sides: 12 mm marine ply with ISI mark or MS plates with Soldiers
 Column side vertical runner: 75 x 37.5 mm or 75 x 50 mm
 Column side horizontal walers: 75 x 75 mm or ISMC
 MS supports: MS props
4) Shear walls
 Shear wall sides: 12 mm marine ply with ISI mark or MS plates with Soldiers
 Shear wall vertical runner: 75 x 37.5 mm or 75 x 50 mm
 Shear wall horizontal walers: 75 x 75 mm or ISMC or spans
 Inclined / horizontal supports: Props
5) Footings
 Footing side: 12 mm thick marine ply
 Footing side runner: 75 x 50 mm
 Footing side supports: MS Props

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Periodic Inspection:
1) Props and Spans:
Form work Inspection Acceptance criteria Frequency of

material inspection
Props (steel) Condition of top plate Not bent At the time of
/ Prop head approval of material
Condition of base Not bent and properly secured and thereafter every
plate 5 repetitions
to prop
Min 12 mm dia
Locking pin No rust, in plumb and proper
Condition of outer & gauge throughout can be
inner opening opened with ease
Props (wooden) Diameter Not less than 12 mm from At the time of

(wooden props designated dia approval of material
shall be used only Crack Not more than 1/3rd the length and thereafter every
where height of of the prop 5 repetitions
structure is less
Straightness Deviation from verticality not
than 2.4 meter)
more than 1:15
Condition Wood should be dry and hard
H frames Diameter of props As per manufacturer’s At the time of
bracing, gauge of specification and approved in approval of material
props, pins, base design and thereafter every
plates, dimensions & 5 repetitions
welding of joints.
Spans Welding Welding Welds to be proper At the time of
Bolts In place and operational approval of material
and thereafter every
Top / Bottom Not damaged & corroded

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members Not damaged & corroded 5 repetitions

Top / Bottom plates Not bent
Top end plates Plates should move freely
Oiling
2) Slab Bottom
Form work Inspection Acceptance criteria Frequency of

material inspection
Ply Warpage Within acceptable limits visible Refer note below
Surface Rough surfaces should not
exceed 5% of area
Delamination No delamination should be
observed
Edges Should be straight &
undamaged
Runners Cross section Not less than 5 mm of the Refer note below
designed width and + 3 mm
for depth
Warpage Should not be more than 5
Cracks mm
Not allowed
Centring Plates Bends Not more than 5 mm Refer note below
with angle Welds of stiffeners Should be proper
NOTES:
For New Formwork Material:

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First inspection shall be done at the time receipt, second inspection after first 5 repetitions and
thereafter every 2 repetitions.
For Old Formwork Material:
First inspection shall be done at the time before first installation, thereafter every 2 repetitions.
General:
Before using all the wooden Chavis / struts / fails and wailings etc. it must be ensured that they are
Randha (planer) finished so that no undulations come on RCC surface. Before using any new or old
shuttering material on site, contractor must get their material checked and certified from Quality
Assurance Department. The rejected material must be removed from site or stored separately.
Procedures:
A) Procedures to be followed before and during erecting formwork:
1) Sequence and mode of construction shall be pre decided to make optimum use of available
formwork.
2) All staging members (props) shall rest on compacted ground / continues wooden plank for the
construction of first slab. Where steel props are used, they shall be braced in both directions using steel
tubes and couplers. In addition, cross bracing shall be provided as per design. Props shall be erected in
plumb.
3) Props shall rest on cleaned slab surface. Packing below props shall be avoided. For staircase, props
should be placed vertical and wedges should be provided to maintain verticality.
4) If pins provided by manufacturers are not used (if pins are lost or misplaced) then use of minimum 12
dia. tor steel pins shall be allowed.
5) Spans shall be erected as per correct spacing given in design and shuttering plates shall be placed
tightly abutting each other. Overlapping portion of open spans shall be tightened with the help of 2 nos.
of bolt. (16 mm dia) In no case, overlapping portion shall be smaller than 450 mm to 600mm or as
specified by manufacturers. Spans shall be supported only at ends and not in between.
6) Gaps (Gabadi) in formwork shall be restricted to 5% of area of slab. Gaps less than 5mm should be
sealed with masking tape or cement grease or equivalent with approved gap sealer / sealant. If gap
found more than 5mm, ply rib of required size or equivalent should be used. Ensure that ply and ply rib
is maintained at same line and level.
7) Independent scaffold shall be erected for fixed forms, reinforcement placing, concrete pour etc.
Adequate camber, if specified on drawing, shall be given to the erected formwork. (Camber at the beam
bottom shall be provided at the rate of 1mm per Running Meter of clear length.)

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8) Bearer beam (of wood), shall be provided below beams at the prop location and they shall be
supported by props. The first support to beam shall be at 9” from RCC face. Beam side forms shall be
erected in plumb. Width of beam / shear walls shall be maintained using tie bolts / spacers of correct
diameter and length. Tie bolts shall be enclosed in PVC conduits with provision of removable plastic
cones with coil nut at ends. Inclined struts shall be erected as specified. Inclined strut can rest on bearer
beams or rest against laffas nailed on slab.
9) For footings, gap between side ply and PCC shall be sealed to make joints leak proof. For vertical
Members, a platform shall be erected not touching the side forms of vertical members for concrete
purpose.
10) For all concrete works, forms shall be kept above concrete level and inside of forms shall be marked
to indicate concrete level. For casting of columns, shear walls, lift pardi forms shall be kept projecting at
least 4” above concrete level so that next pour can be cast with a leak proof joint.
11) For all erected formwork, levels shall be checked with auto level. Fine correction shall be done in
level through adjustable steel props or adjustable prop heads. It is recommended that Site Engineer gets
mock up for walls and columns done and approves the same before starting of erection of formwork.
12) After placing of reinforcement in position, form surface shall be cleaned before concreting. Wooden
planks shall be provided over reinforcement as walkways to carry concrete to edged beams.
13) Scaffolding shall be either single scaffolding or double scaffolding as specified. Making of holes in
masonry should be avoided. For night work adequate lighting arrangement shall be provided.
14) For larger heights H frames shall be erected. The spacing of H frames shall generally be 2.0m to
2.5m. H-frames shall be connected by cross bracings and shall be provided with wooden planks / steel
gratings. H-Frame shall be used with stirrup heads and I / C section at top and proper packing should be
given to keep in position. Stirrup head should be opened only up to 60 % of its total length.
15) In no case part of column below beam bottom level should be cast along with slab / beam
concreting. All columns must be cast exactly up to beam bottom level. If small top portion of column
concreting is balance, then the same should be concreted separately before taking up beam bottom
shuttering.
16) Spacing between wailers of sides of beams or columns should be within 9” to 12”.
17) Any column with 2’-0” width or more should have tie-bolts at every yoke or 3 nos. bolts if vertical
chavi or angle is used.
18) For external columns and beams and crank beam of staircase, the alignment should be maintained
by using turn-buckle with wire rope only.

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19) Checking of shuttering for slab Level marking should be transferred on column dowels at 2’ height,
line Dori should be fixed up and level of slab to be checked in three dimensions i.e. Length, Breath &
diagonally.
20) 25mm thick wooden Dhar phalli shall be minimum 4” width all around slab gala, i.e. along periphery
of all internal beam sides so that one side will rest on internal beam side and other side on 3” X 3”
Chavis having prop supports at 2’ – 0” c/c.
21) Small span slabs such as passage and toilets should have ‘Double Chavi’ (Two-way chavi) supporting
systems, alternatively, if single chavi is used, it (each) should be supported on minimum 3 nos of props.
22) Shuttering for peripheral / external elevation beams
(a) 3” X 3” cantilever chavi should be provided through beam bottom @ 18” c/c. on which platform with
2 no’s of 9” wide plank should be fixed all along the peripheral beams as a working platform.
b) 3” X 2” or 3” to 4” X 1 ½” or 2 ½” dia props pieces as racker support should be provided at 18” c/c
with this or continuous chavi support fixed on cantilever chavi.
c) 3” to 4” X 1 ½” wooden chance lafa will be provided connecting both beam sides at top to keep
straight and at required beam width.
23) Shikanjas should be fixed to each strut of beams at 18” c/c to the full area, which is to be concreted.
Shifting of shikanjas should not be permitted from one part to another part while concreting is in
progress for further areas.
24) To avoid leakages of slurry from shuttering at column / beam junctions, studs / struts from beam
sides should be taken down over the column side and should be gripped between two horizontal chavi,
on both sides of columns with bolts, nuts and clamps. No nailing is permitted. Refer Drawing for the
same as below.
25) Spacing between wailing of sides of beams or columns should be within 9” to 12”.
B) Procedures to be followed after erecting formwork:

1) Just prior to concreting all levels shall be rechecked. It shall be ensured that all fittings are tight. All
tolerances in form work shall fall within the limits mentioned in acceptance criteria.
2) During concreting, strict supervision shall be maintained on overall erected formwork. If any sinking
or displacement is observed during concreting, remedial measures shall be adopted immediately.
C) DE shuttering of formwork:
1) DE shuttering shall be done only with the prior approval of QA Department. Recommended DE
shuttering periods are mentioned in table below. But this may vary depending on type of cement being
used, strength of concrete achieved on the day of DE shuttering, type of form used etc.

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2) Sequence of removal of props and other components shall be done as per instruction of QA
Department’s recommendation.
DE shuttering period after casting:
Formwork DE shuttering Period
16 – 24 hrs. (after checking final setting time of
Sides of column
concrete)
Sides of footings
concrete)
Sides of slab
concrete)
Slab supports
1) spanning up to 4.5 m 7 days
2) spanning over 4.5 m 14 days
Beam supports
1) spanning up to 6 m 14 days
2) spanning over 6 m 21 days
Cantilever 21 days
Acceptance Criteria for Erected Formwork:

Formwork DE shuttering Period
Dimension of column and beams in cross-
+12mm /-6mm
section
Footing dimensions in plan +50mm /-12mm
+0.02 times width of footing in the direction of
Eccentricity of footing
deviation but < 50mm.
Thickness of footing +0.05 times thickness of footing
Skin plate 1.5 mm
Surface flatness for a single member
Span up to 1.5m +3mm /-3mm
1.5m to 3.0m +6mm /-6mm or span / 360 whichever is less

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3.0m to 4.5m +9mm /-9mm

4.5m to 6.0m +12mm / -12mm
For every additional 6m +6mm / -6mm
Camber for beams and slabs 1 in 500 or as per RCC Consultant
+50mm / -50mm
Clamps for columns / beams
Formwork Drawing and Specification:

Table 1:
The following table shows the sizes of runners, vertical struts and inclined struts required for beam
formwork system and spacing of the same:
Size of Runners (mm)
Depth of No. of Size of Strut
75 X 37.5 100 X 37.5 75 X 50 50 X 75
Beam (mm) Runners (mm)
Spacing of Vertical / Inclined Strut (feet)
300 2 4.0 4.0 5.0 6.0
100 X 37.5
400 3 3.75 4.0 4.5 5.5
75 X 50
500 3 3.25 3.5 4.0 5.0
600 3 3.0 3.25 3.75 4.75
700 4 3.25 3.5 4.0 5.0 75 X 50
800 4 3.0 3.25 3.5 4.5
75 X 75
900 4 2.75 3.0 3.25 4.25
50 X 75
Beam side Formwork system:

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Beam Formwork System:
Refer Table 1 for sizes of different members
Details of Joinery at section B from above diagram:

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For Inner beam if beam side forms are greater than depth of beam:
Refer Table 1 for sizes of different members

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Table 2:
The following table shows the sizes and spacing of Walers for Column formwork:
Size of Walers Length of

Centre to Centre Spacing of Walers
(mm) Column - L
75 X 75 1m 6” 6” 9” 9” 12” 12” 18” 18”
50 X 75 0.9 m 6” 12” 12” 18” 18” 24” --- ---
Vertical Runners
at 150 c/c for 12 0.8 m 6” 12” 18” 24” 24” --- --- ---
mm thick ply 0.7 m 6” 18” 24” 24” 24” --- --- ---
75 X 50 0.8 m 6” 6” 9” 9” 12” 12” 18” 18”

Vertical Runners
0.7 m 6” 12” 12” 18” 18” 24” --- ---
at 150 c/c for 12
mm thick ply 0.6 m 6” 12” 18” 24” 24” --- --- ---
0.5 m 6” 18” 24” 24” 24” --- --- ---
Table 3:
The following table shows the sizes and spacing of Form members for shear wall / lift pardi:
Height of ISA / ISMC from floor level

Size of Vertical Permissible Total No. of
Batten (mm) Overhang ISA / ISMC
1 2 3 4
75 X 37.5 2 feet 4 Ground 2’ 4’ 6.5’
75 X 50 2 feet 3 Ground 3’ 6.5’ ---

Formwork system for Column Starter:

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Column Formwork Elevation:

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Column Formwork System:

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Plan at Intermediate Height for Columns:

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Alignment of Tie Rod in Column Formwork System:
Elevation of ISMC / ISA alignment:

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Side Elevation of ISMC:

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Plan of Tie Rod Arrangement:

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Typical Sketches and information of shuttering accessories

1) Cantering Sheet:
Wide range of Cantering Sheet/Floor Form are available that are manufactured with 2 mm sheets which
has been folded on all four side with suitable slot provided with stiffener. These are available in standard
sizes of:
1) 900 x 600 mm 2) 1150 x 600 mm 3)800x 600 mm
2) Wall Form
Wall Form can be customized as per the specification of different projects. These are developed in
compliance with various industrial standards and are available in standard sizes such as:
 Length: 1250 mm / 2500 mm
 Width: 300, 350, 400, 450, 500, 600 mm
3) Flexible Panel

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Flexible Panel are widely used in various industries. These are available in various standard sizes and can
be customized a as per the specifications of project.
Sizes that can be availed are:
 1250 x 500 mm,
 1250 x 400mm
The Panel details are as follows:
Internal Corner Panel Size: 1250 x 150 x 150 mm
External Corner Panel Size: 1250 mm, 2500 mm long
Channel Soldier Size: 1250 x 100 mm, 2500 mm x 100 mm
Wall adjuster panel size: 1250x150mm/1250x225 mm/1250x350 mm
4)Adjustable Props
Qualitatively superior, these are available in various types. Load bearing capacities have already been
highlighted in the form work section earlier.

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5) Wedge locks Systems

Designed and developed in accordance with the needs of the project, wide range of wedge lock systems
finds varied application in wide number of industries. These are qualitatively superior and can be
customized as per the specifications of projects.
Some features and specifications of the systems are:
 Consist of vertical built of 40 mm NB
 Heavy pipes with wedge housings welded at intervals of 500 mm / 100 mm in four directions at
right angles
 Angular transom tubular ledger, tubular bracing having end fittings with locking wedges will fit into
the wedge housing with hammer
 Maintenance free
 Available in standard sizes

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Upright / Vertical : 2 meter, 3 meter

Tubular ledger 2 meter : 2.5 meter
Angular Tubular transom : 1.25 meters
6) Formwork System (For RCC Wall)

Formwork System for RCC Wall is available in customized as well as standard sizes and are of two types:
1. For simple RCC wall and
2. For round RCC Wall
For Simple RCC Wall:

 Steel system shuttering
 Standard panels made out of 45 x 30 x 5 mm / 45 x 45 x 5 mm
 Angles suitably slotted with 50 mm
 Intervals, skin plate of 2.5mm
 Thick M.S. Sheet welded to the frame of wall form/channel soldier, internal corner panels
7) H-Frame Scaffolding

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Wide ranges of H-frame scaffoldings are manufactured `in accordance with the need of the projects.
These possess following features and specifications:
 Welding frames of two vertical of 2 m (32 mm. N.B. Pipe)
 Two horizontals of 1.22 m (25 mm N.B. Pipe)
 Frames are inter-connected with bracing at an interval of either 2 m or 2.5 m through pins welded
on frame and locked suitably
8) Tube Scaffolding & Fittings

Following types of scaffolding & fittings are available:
 Double Coupler: For connecting 40 mm N.B tubes at a right angle.
 Swivel Coupler: Used to connect 40 mm N.B. pipes at any angle.
 Expanding Joint Pin: Suitable to connect 40 mm NB Pipes as Ledgers.
 Fixed Base Plate: Suitable for 40 mm nominal bore steel tubes.
 Adjustable Stirrup Head: Designed for fine adjustment of height between 80mm and 200 mm.

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 PROCEDURES FOR CONCRETING

Step 1 – Mix Design Approval:
Latest mix design for concrete shall be available on site. Mix Design and trials of mix shall be carried out
as per the requirements of SANS to check workability, setting time, actual density, strength and cement
consumption (yield) whether it is site produced concrete or ready-mix concrete. For site produced
concrete, all the concrete ingredients viz. Cement, Mineral admixtures like fly ash, GGBS etc., Silica
fume, Water, Aggregate, Chemical admixture etc. used should satisfy the requirements for the safety,
structural performance, durability and appearance of the finished structure, taking full account of the
environment to which, it will be subjected. The selection and use of materials shall be in accordance
with SANS and all materials shall meet the requirements of relevant BIS specification. If Ready Mix
concrete has to be procured following specification shall be followed by the supplier of ready-mix
concrete supplier:
SPECIFICATION FOR SUPPLY OF READY-MIX CONCRETE

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1) All the concrete ingredients viz. Cement, Mineral admixtures like fly ash, GGBS etc., Silica fume,
Water, Aggregate, Chemical admixture etc. used should satisfy the requirements for the safety,
structural performance, durability and appearance of the finished structure, taking full account of the
environment to which, it will be subjected. The selection and use of materials shall be in accordance
with SANS and all materials shall meet the requirements of relevant BIS specification.
2) All the mix designs shall be approved by Client & MES. And our structural consultants where ever
required. It is essential to carry out laboratory trials and complete data of trials shall be submitted for
approval. Laboratory trials shall generate base data on 1 day, 3 days, 7 days, 28 days, 45 days and 56
days compressive strengths for the selected set of ingredients. Attempt should be made to establish
correlation between these strengths. The correlation will change if the source of any ingredient is
changed, in which case a fresh correlation should be established and approval should be taken for the
new mixes. MES & client Representatives shall be allowed to witness such trials.
3) Minimum Cement Content, Maximum Water Cement Ratio and Maximum Cement Content shall be as
per the requirements of SANS with respect to the exposure conditions specified their in.
4) Client & MES requirement of workability at the pump point as measured by slump test shall be
between 140-160 mm, so that after pumping to the desired location the slump is minimum120 mm. Any
concrete shall be designed for a minimum three hours retention/open time. The workability of the
concrete shall be controlled on a continuous basis during production and any corrective action
necessary taken. No additional water, other than the amount required to produce the specified grade of
concrete as per mix design, shall be added to the truck mixer drum before discharge unless specifically
requested and signed for by MES & Client representative. Re-dosing or split dosing shall be allowed
subject to the written permission of trained technicians and Engineers from MES & client... In any case,
the total dose should not exceed the maximum dose of admixture declared by Supplier or
recommended by Admixture supplier. The supplier shall stock at least 50 litres of admixture with MES &
Client Quality Control department at site.
5) Any concrete poured should get finally set within maximum 24 hours.
6) Any concrete of a specified Grade shall meet the characteristic strength in 28 days. Any concrete
being supplied to our site, which does not achieve minimum characteristic strength at 28 days, shall be
considered as failure and no other acceptance criteria shall be entertained.
7) It is important to maintain the water cement ratio constant at its correct value. The amount of added
water shall be adjusted to compensate for any observed variations in the moisture contents in the
aggregates. Suitable adjustments should also be made in masses of the aggregates due to this variation.
Any change in water content due to change in aggregate grading shall be taken care of by forward
control by suitable modifications to mix design.

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8) Batch sheets, moisture correction calculation/sheet shall be submitted along with challahs for every
pour of concrete. The scope of addition of extra admixture (over and above the quantity which has
already been added at the time of batching at plant) shall be declared by concrete supplier. Immediately
before discharging the concrete at the point of delivery, the producer or his representative shall provide
MES & client representative with a pre-printed delivery ticket for each delivery of concrete on which is
printed, stamped or written the minimum information detailed below. The delivery ticket will form the
basis of invoicing. The following information shall be included in the delivery ticket to accompany the
load to MES & client:
 Name or number of the ready-mixed concrete depot.
 Serial number of the ticket.
 Date.
 Truck number.
 Name of the Purchaser, Name and location of site.
 Grade or mix description of the concrete.
 Specified target workability.
 Minimum cement content (if specified).
 Type of cement and grade (if specified).
 Maximum free water-cement ratio (if specified).
 Nominal maximum size of aggregate.
 Generic type or name of any chemical and mineral admixtures included.
 Workability/Slump at plant
 Admixture dosage added at plant
 Quantity of concrete in cubic meter.
 Time of loading.
 Signature of the plant operator.
On site the following information will be added:
 Time of arrival on site.
 Time when discharge was completed.
 Any water / admixture added by the supplier to meet the specified workability.
 Any extra water or admixture added at the request of Client & MES representative and his
signature.
 Pouring location.
 Signature of the purchaser or his representative confirming discharge of the load.
9) Ready-mixed concrete shall be transported from the mixer/batching plant to the point of placing as
rapidly as practicable by methods that will maintain the required workability and will prevent

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segregation, loss of any constituents or ingress of foreign matter or water. Concrete shall be transported
in a truck-mixer or agitators unless Client & MES agrees to the use of non-agitating vehicles.
10) For the assessment of compliance of ready-mixed concrete, the sampling may be carried out jointly
by Client & MES and the supplier with its frequency mutually agreed upon. However, it will not absolve
the supplier of his responsibility from supplying concrete as per the requirements given in standards
(SANS) or otherwise mutually agreed terms and conditions. Any special clause mentioned in this
specification shall be binding on supplier of concrete. The point and time of sampling shall be at
discharge from the producer’s delivery vehicle or point of final placement.
11) Concrete mixes shall be randomly sampled and tested for workability, and where appropriate,
plastic density, temperature and air content. Where significant variations from target values are
detected, corrective action shall be taken.
12) Concrete supplier shall submit the following information, reports and test certificates before
approval of mix design and in the event of change of source of raw material:
Source and brand of different ingredients of concrete,
Gradation, specific gravity, water absorption, mechanical properties, deleterious material report
of fine and coarse aggregate,
 Report on alkali silica reactivity and soundness of aggregates,
 MTC of cement/external test report,
 Chemical and physical test report of Fly ash as per requirements of SANS,
 Physical and chemical test report of chemical admixture,
 Water test report for each source,
 Mix Design Stipulations and final mix data,
 Results of concrete mix design trials: Workability at 0, 1, 2, 3 Hrs., Cohesiveness, density, Yield of
concrete, Initial and final setting time of concrete, strength results at 1,3,7,28,45 and 56 days.
13) Concrete supplier shall submit the following information, reports and test certificates on a monthly
basis:
 Change of Source and brand of different ingredients of concrete,
 Correction of Mix design if required,
 Gradation, specific gravity and water absorption for each source of fine and coarse aggregate,
 MTC of cement or external test report,
 Physical test report of Fly ash – Fineness and LOI,
 MTC of each lot of admixture and uniformity test report,
 Water test report if source changes,
 Compressive strength results at 3, 7 and 28 days for all the pours of concrete,
 batching plant calibration report.

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14) Records shall be maintained by the producer to provide confirmation of the quality and quantity of
concrete produced. The records shall be retained for the purposes of these requirements for a period of
at least one year. They shall cover the following aspects:
Production and delivery:

 Batching instructions,
 Batching records,
 Delivery tickets, and
 Equipment calibration and plant maintenance.
Materials and production control:

 Concrete production and materials purchase, usage and stocks, and
 Certificates or test results for materials.
Production quality control:

 Control test results
15) All other requirements pertaining to Materials, Storage of Ingredients, production, delivery, batching
equipment, quality control, sampling, order processing etc. as specified in SANS – “READY MIXED
CONCRETE-CODE OF PRACTICE” shall be binding on the producer / supplier of concrete.
16) Any additional compliance criteria (project specific) shall be declared to the producer by MES &
SVHL’S. prior to supply and shall be mutually agreed upon in terms of definition, tolerance, frequency of
assessment, method of test and significance of result. If there is any specific requirement other than
above requirements like temperature control, early strength etc. for a particular project, such
requirements shall be intimated to the supplier by MES & SVHL in advance.
17) The action to be taken in case of non-compliance shall be declared and mutually agreed upon.
18) In case of failure of strength (as estimated by cube strength), Cores shall be drilled out from the
structure with strength failure and shall be tested for compressive strength and equivalent cube
strength must meet the requirements of relevant BIS standard. No other NDT shall be entertained. The
cost of Core drilling and testing shall be borne by the supplier of concrete. Further the results shall be
forwarded to MES & Structural consultant for his opinion and his decision shall be binding on both the
parties – Client & MES and the Supplier of concrete.
19) If the equivalent cube strength of the drilled cores does not meet the requirements of BIS codes,
then the matter shall be referred to MES / Client structural consultant and as per the recommendation

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of the Structural Consultant, the structure shall be demolished and reworked or strengthened. The cost
for such demolition/ breaking, reworking including cost of labour and material such as steel
reinforcement, concrete, electricity etc. or the cost of strengthening the structure shall be borne by the
supplier.
Step 2 – Site Preparation
Dewatering of area to be concreted shall be carried out if required. Also, area shall be cleaned of any
dirt, debris, waste material, binding wires etc.
Step 3 – Pre-Concreting Checks
1) Necessary latest drawings shall be made available on site.
2) Checking of form work, supports and scaffolding shall be done as per the available latest drawings.
3) Checking of various activities such as reinforcement, cover blocks, embedded electrical conduits,
plumbing lines, inserts etc. shall be done as per drawing.
4) Sequence of concreting and location of stopper shall be decided and clearly marked on drawings
available on site.
5) Moisture correction for sand shall be calculated and net quantity of water to be added per bag of
cement shall be decided to maintain water cement ratio as per mix design.
6) Wetting of coarse aggregates shall be carried out 24 hours before actual concreting in case of site
produced concrete.
7) Availability of necessary raw materials and equipment shall be ensured.
8) Appropriate de-shuttering agent should be applied on formwork.
9) Checklist / QA card should be appropriately filled taking into account all the points are maintained
properly at site.
10) In case of site produced concrete, concreting shall be preferably done on weight basis. However, if
volume batching has to be resorted to, conversion into volume shall be done by calculating DLBD of
coarse / fine aggregates and also taking into account Bulk age Factor for sand.
11) Pharma’s of correct sizes shall be prepared and maintained in proper condition in such cases.
12) Sufficient concrete handling, compaction (vibrators) and curing arrangements with respect to size of
the pour, depth of pour, spacing of reinforcement etc. must be ensured before starting concrete if site
produced concrete or before ordering concrete from approved supplier.
Step 4- During Concreting Checks
General:

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1) Before starting concrete for the day, the gradation of fine and coarse aggregate shall be checked and
if any deviation in combined gradation is observed, necessary corrections in percentage of aggregates
shall be made to achieve the desired combined gradation. This will ensure that concrete is cohesive and
free from segregation and bleeding.
2) The concrete pipeline of pump shall be checked to ensure whether there is any leakage of slurry,
which may affect the pumpability of concrete.
3) During concreting it must be checked whether there is any slurry leakage from the shuttering and
corrective measures should be taken immediately because this may affect finishing because of
honeycombing and final performance of the concrete and aesthetics.
4) Variation in pipe diameter of pump and number of bends in the pipeline should be restricted to
minimum.
5) The supports/props must be checked during concreting to avoid bulging and potential failure of
shuttering because of the weight of wet concrete.
6) Pouring height must be restricted as per the site condition with suitable methods to avoid segregation
of concrete.
7) Availability of sufficient equipment and manpower for compaction of concrete must be ensured
8) Vibrator needle size shall be appropriate as per the spacing of the reinforcement and workability of
the concrete. Influence radius should be checked by visual observation.
9) Over vibration of concrete should be avoided, which may lead to deposition of slurry at the top
leading to crazing cracks any time during hardening. Over vibration may also lead to bleeding resulting in
plastic settlement and subsequent cracks.
Site Mixed Concrete:
1) Weights of aggregates shall be adjusted in the first 5 batches to get required slump, without changing
the water cement ratio given in the mix design.
2) Corrections shall be done in the mix proportions (aggregates, sand volume correction) to get cohesive
homogeneous mix of desired workability.
3) Batching shall be done by sandwiching the cement between fine and coarse aggregate. Preferable
sequence is coarse aggregate, cement and then sand.
4) Minimum mixing time of 1½ minutes shall be adhered to, for every batch of concrete. Hence
maximum output of mixer shall not exceed @30 bags per hour, if one bag mixer is used.
5) Unloading of concrete mix shall be done on MS tray / concrete platform.
6) Slump reading shall be recorded after every 25 bags and slump variation shall not exceed 25mm from
the designed workability.

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7) Presence of qualified supervisor at the weigh batcher / concrete mixer, at place of concreting and at
shuttering shall be required.
8) First batch of concrete shall be prepared by addition of 10% extra cement to allow for loss in the
drum.
9) Exact quantity of water as per moisture correction applicable shall be added using water dispenser /
calibrated cans. Buckets shall not be used.
10) Concreting works shall be arranged so as to have minimum cold joints.
11) While pouring concrete, segregation of concrete shall not be observed.
12) Cubes shall be taken during every concreting. Number of samples and testing shall be in accordance
with SANS. Each cube shall have proper identification mark as regards grade, date of casting, location
etc. Cube sampling shall spread over entire period of concreting.
13) While cubes are being taken for testing, corresponding slump shall also be recorded, in cube testing
register. Cubes shall be cast in the presence of Engineer.
14) During every day’s concrete unit weight of concrete as specified in SANS shall be checked and
compared with theoretical density of concrete (sum of weight of all ingredients). If any significant
deviation is observed, it indicates corrective measures are required in Concrete Mix Design.
15) In case of pre stressed concrete more no. of cubes shall be casted for estimation of desired strength
on the day of stressing.
16) At high altitudes wind breakers shall be provided while concreting.
Ready Mix Concrete:
1) Transit trucks shall comply with the relevant code, with an agitating speed between 2 and 3 RPM and
mixing speeds in the range of 10-20 RPM.
2) Before unloading of any truck at the site, the RMC supplier shall supply a certificate/batch sheet (a
computerized sheet) along with moisture correction for the concrete, mentioning proportions of all the
ingredients, w/c ratio, dosage of plasticizer and relevant admixtures etc. (please refer Specification for
Supply of RMC).
3) The maximum water cement ratio, as specified in the approved mix design shall not be exceeded.
4) The information provided by RMC supplier shall be cross checked at site, and in all cases, slump shall
be taken prior to concreting. The accuracy of the measuring equipment shall be within + 2 percent of the
quantity of cement and mineral admixtures being measured and within + 3 percent of the quantity of
aggregate, chemical admixture and water being measured.
5) Concrete which needs to be pumped shall have workability between 120 to 150 mm or as specified
when the transit mixer arrives. Any concrete shall be designed for a minimum three hours

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retention/open time. The workability of the concrete shall be controlled on a continuous basis during
production and any corrective action necessary shall be taken. No additional water, other than the
amount required to produce the specified grade of concrete as per mix design, shall be added to the
truck mixer drum before discharge unless specifically requested and signed for by MES & Client
Representative. Redoing or split dosing shall be allowed subject to the written permission of trained
technicians and Engineers from Client & MES. In any case, the total dose should not exceed the
maximum dose of admixture declared by Supplier or recommended by Admixture supplier.
6) It shall be ensured that the retardation time achieved by the use of admixtures does not exceed the
time required for transit and actual placement of concrete. This shall be achieved by checking the time
of dispatch of transit mixer mentioned on challan. Any Concrete is being designed with the help of water
reducing agents and retarders for a stipulated retention time. So, the concrete must be consumed
within the same time as considered in design. Our all-concrete mixes must be designed for 3 hours
retention time, so concrete must be consumed within 3 Hours from the time of batching. If the
workability of concrete is higher than desired workability and segregation & bleeding is observed, we
should allow some time to elapse before discharge till workability drops to the range of 120 to 150 mm.
If workability is less, then re-dosing or split dosing shall be allowed but, in any case, the total dose
should not exceed the maximum dose of admixture declared by Supplier of concrete or recommended
by Admixture supplier. We must avoid over dosing which may cause delay in setting of concrete
7) Temperature of concrete at the time of pumping shall be less than 40ºC or as mutually agreed
between MES & Client. and Supplier of Concrete.
8) The cohesiveness and mixing of the concrete should be checked, there should be no lumps, bleeding
or segregation in the concrete.
9) During every day’s concrete unit weight of concrete as specified in SANS shall be checked and
compared with theoretical density of concrete (sum of weight of all ingredients). If any significant
deviation is observed, it indicates corrective measures are required in Concrete Mix Design. Supplier of
concrete shall be immediately informed as this variation may impact yield of concrete or desired
properties of the concrete
10) Concrete carrying pipes shall not be allowed to rest on top reinforcement which is likely to bend.
Leakage of slurry from concrete pipeline should be checked and rectified.
12) At high altitudes wind breakers shall be provided while concreting
Footings
1) PCC should be done in level as per given size in drawing with Dobra marking.
2) Demarcation of foundation should be done with correct orientation of column as per centre line plan.

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3) All footings shall rest on PCC of M15/M10 Grade concrete, having minimum thickness of 150mm /
75mm or as per drawing.
4) Concrete shall be cast in max 450mm layers and vibrated by 60mm vibrating needle.
Columns and Shear walls
1) Platform erected for labour for concreting shall be independent of column shuttering.
2) If required, Grade of concrete for column starters shall be one grade higher than that of column
concrete.
3) Minimum height of starters shall be 6” to 9” and shuttering shall be of fabricated steel / steel
channels or plywood. (Planks or fali should not be used in sides of starters.) Concrete within shall be
suitably vibrated and cured.
4) Formwork for starters of column / shear walls when erected shall be checked using theodolite / line
dori for the correctness of dimensions and orientation (including offsets if any).
5) Thick Mortar slurry of 1:1 cement sand mix shall be poured at base of columns to prevent
honeycombing. This mortar slurry shall have water cement ratio 0.05 less than that recommended for
concrete mix.
6) Concrete for columns shall be cast and vibrated in layers of 450mm.
7) Column concreting shall be done up to lowest level of beam bottom at the junction.
8) Concrete key shall be made at top surface of column for better bond with next pour/ 20mm metal
packing shall be done on top of concrete surface for proper bonding with next pour / chipping of top
surface for removal of laitance.
9) If reinforcing bars are congested at the junction of column and beam, a special concrete mix of higher
grade using 10mm aggregates may be used therein.
Slab and Beams
1) Concrete from hoist shall be unloaded on MS tray
2) Walking platforms shall be provided for easy movement of labour without disturbing the
reinforcement.
3) Level marking / ghodi having height equal to thickness of slab shall be used while slab concreting is in
progress.
4) Concreting area for the day shall be well demarcated and concreting shall commence from the
farthest end and proceed towards direction of hoist. In case of pumping, proper planning should be
done for placing of concrete.

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5) Slab top levels shall be checked during and after finishing with levelling instrument for controlling the
thickness of slab.
6) Beams and slabs having depth more than 150 mm shall be vibrated by 25/40/60 mm needle
depending on size of beams and spacing of reinforcement, whereas slabs having thickness of less than
150 mm shall preferably be vibrated by surface vibrator. The spacing of inserting the vibrating needle in
concrete shall be as follows:
 25mm needle – 150mm c/c
7) Care shall be taken not to over/under vibrate the concrete. While withdrawing vibrator needle no
holes
shall be visible in concrete.
8) Concrete shall be placed in layers not exceeding 450mm deep in deep beams and placed to the full
depth in
slabs and small beams. Each layer shall be placed and well compacted before the preceding layer has
taken its
initial set and in a manner that will entirely prevent any cold joint forming between the layers.
9) If concrete is being placed by pump or crane bucket, concrete should not be poured directly in to the
beams.
10) If grade of concrete for slab and columns is different, column portion shall be cast first before slab
concreting starts. Care shall be taken to prevent formation of cold joint at junction i.e., portion adjoining
columns shall be cast before initial setting starts in columns. Welded wire mesh or equivalent shall be
used as stoppers to prevent excess concrete from columns to flow into beams.
11) Construction joint in beams shall be provided as per drawings or in absence of such drawings, where
shear force is zero. Cement sand slurry of 1:1 with bonding agent shall be used at construction joints to
create better bonding between old and new concrete. At construction joints, new concrete shall be
over-vibrated for proper bonding with old. Wooden stoppers with step shall be provided at construction
joints in such a way so as to facilitate their easy removal.
12) Slab panels shall be covered with wet Hessian cloth, tarpaulin or plastic sheets immediate after
concreting, after initial set occurs, to prevent formation of shrinkage cracks.
Step 5- Post Concreting Checks
Curing

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1) Curing is the process of preventing the loss of moisture from the concrete whilst maintaining a
satisfactory temperature regime. For all concrete works, curing shall be start immediately after DE
shuttering and for slab and raft surface immediately after initial setting of concrete by sprinkling or
covering with wet hessian cloth.
2) Exposed surfaces of concrete shall be kept continuously in a damp or wet condition by ponding or by
covering with a layer of sacking, canvas, hessian or similar materials and kept constantly wet for at least
7 days from the date of placing concrete in case of ordinary Portland Cement and at least 10 days where
mineral admixtures or blended cements are used.
3) The period of curing shall not be less than 10 days for concrete exposed to dry and hot weather
conditions & 14 days where blended cement is used.
Protection of concrete
1) Newly placed concrete shall be protected from rain, sun and wind by approved means viz: Hessian
cloth, plastic sheets etc.
2) Concrete placed below the ground level shall be protected against contamination from falling earth,
during placing.
3) The area in and around the actual place of the concreting shall be kept sufficiently dry, by
constructing sufficiently watertight forms / cofferdam around the area to be concreted, to prevent loss
of mortar through walls.
4) Continuously dewatering the area throughout the period of concreting and till initial set of concrete
occurs with the help of dewatering pumps shall not be resorted to.
Columns / Shear walls
1) Curing shall be done keeping the concrete surface wet by covering it with moist double Hessian cloth
2) Curing shall continue for at least 10 days.
Slabs
1) Curing of slabs shall be done as mentioned above.
2) Ponds shall be made within 24 hours of slab casting and till then slab shall be cured by spraying water.
3) Ponds shall be made at column locations first to cover from all sides and then to cover other portions
of slab.
4) Care shall be taken to see to it that ponds are completely filled with water throughout the
recommended period for curing.
5) Vertical faces of the beams and area of slab outside ponds shall be cured by covering with wet
Hessian cloth.

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6) In case where ponding is not done, whole slab should be covered with wet hessian cloth and care
should be taken to keep it moist always.
Footings
1) Flat portion of footings shall be cured by covering it with wet double Hessian cloth.
2) For flat portions of Rafts, curing shall be done in a similar way as that for slab and vertical faces shall
be cured similar to the columns.
General:
1) All the flat portions of footings / underground structures shall be applied an epoxy based bituminous
layer for protection against ground water.
2) RCC surface (footing faces, plinth beam sides, below PCC, periphery of the building) below ground
level should be given approved anti-termite treatment.
3) Backfilling shall be started after footings are cured. Backfilling shall be carried out in layers of 300mm
to 450mm thick good quality Laterite, which shall be well watered (up to Optimum Moisture Content)
and compacted by using mechanical vibrator.
4) Date of casting should be displayed on concrete surface with identification after de-shuttering to
monitor curing.
5) If honeycombs observed are of repairable nature (which do not require demolition of member, in the
opinion of Structural Consultant), the same shall be rectified by using approved non shrink mortar mixed
with bonding chemical.
6) If it is intended to have plaster or masonry against the concrete structure, the surface shall be hacked
(approx. 60/70 hacks each 2-3mm in depth, 1” length and 1” apart per sq. Ft) within 48 hrs. After de-
shuttering or it is preferable to use approved bonding agents instead of hacking.
7) Reinforcement bars projecting above cast concrete shall be cleaned, using wire brush.
8) Tie roads and PVC pipes must be removed immediately after de-shuttering.
9) Columns below natural ground should have 20mm additional covering or as recommended by
structural consultant and Winged Cover Kanda should be used to maintain alignment of reinforcement
and covering.
Step -6 Concrete Cube Sampling
Site Mixed Concrete:

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The minimum frequency of cube casting shall be as follows if concrete is produced at site mixer. Each
sample shall consist of 3, 6 or 9 cubes depending on whether cubes shall be tested at only 28 days or 7 &
28 days or 3,7 and 28days.
Concrete Quantity Number of samples
3
Up to 5 m 1
3 3
6m to 15m 2
3 3
16m to 30m 3
3 3
31m to 50m 4
4 + one additional for each additional 50 m 3 or
More than 50m3
part thereof
Ready Mix Concrete:

For the assessment of compliance of ready-mixed concrete, the sampling may be carried out jointly by
Client & MES. And the supplier with minimum frequency as specified in IS 4926:2003 or otherwise
mutually agreed upon. However, it will not absolve the supplier of his responsibility from supplying
concrete as per the requirements given in standards (SANS) or otherwise mutually agreed terms and
Conditions. The point and time of sampling shall be at discharge from the producer’s delivery vehicle or
point of final placement.
Concrete Quantity No. of Samples to be taken

Up to 50 cu.m. or 50 batches whichever is of One Sample
higher frequency
More than 50 cu.m. One additional sample for every 50 cum. or 50
batches whichever is of higher frequency
The sampling methodology from Transit Mixer shall be as follows:

Let very first concrete go – at least the first one third of a cubic meter of concrete.
• Take a scoopful from part 1

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Let the last concrete go. Thoroughly remix this composite sample either on a mixing tray or sampling
bucket. Then we should proceed with required testing.
Step-7 Casting and testing of Cubes:
For the assessment of compliance of ready-mixed concrete or site mixed concrete, the point and time of
sampling shall be at discharge from the producer’s delivery vehicle to pump or site or discharge from
mixer respectively.
The following steps should be observed:
(a) Check if moulds are cleaned & lightly oiled.
(b) In assembling the mould for use, the joints between the sections of mould shall be thinly coated with
mould oil and a similar coating of mould oil shall be applied between the contact surfaces of the bottom
of the mould and the base plate in order to ensure that no water escapes during the filling.
(c) Ensure angle between adjacent internal faces & between internal faces shall be 90°C + 0.5°C.
(d) Thoroughly remix the sample shovelling into a heap
(e) Fill the mould with concrete in 50 mm layers
(f) 35 tamps for each of the three layers in 150 mm mould or vibrating table
(g) After filling each layer tamp sides with a wooden mallet to expel out any entrapped air
(h) The workability of concrete at time of filling cubes should be between 75 -100 mm.
(i) Remove surplus concrete & number the moulds for identification & record details.
(k) Cover each mould with damp cloth / Hessian cloth immediately after initial set.
(l) Store at a place free from vibration. Protect the cube moulds at all times from high / low
temperatures & driving winds.
(m) Complete Sampling & cube making certificates or records.
(n) After de-moulding the cubes shall be immediately submerged in clean, fresh water or saturated lime
solution and kept there until taken out just prior to test (Temperature 24°C to 30°C).
(o) The specimens shall not be allowed to become dry at any time until they have been tested.
(p) The testing machine may be of any reliable type, of sufficient capacity for the tests and capable of
applying the load at the rate of 14 N/mm 2/minute. The permissible error shall be not greater than ± 2 %
of the maximum load.
(q) The bearing surfaces of the testing machine shall be wiped clean and any loose sand or other
material removed from the surfaces of the specimen which are to be in contact with the compression
platens.

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(r) The specimen shall be placed in the machine in such a manner that the load shall be applied to
opposite sides of the cubes as cast, that is, not to the top and bottom.
(s) Average of three values shall be taken as the representative of the batch provided the individual
variation is not more than ± 15 % of the average.
(u) If failure is observed during the testing of the first cube, stop testing the balance two cubes,
immediately inform the senior authority of Client & MES. And the supplier of the concrete and test the
balance two cubes in presence of the supplier’s authorized representative and have a joint record.
(v) The following information shall be included in the report on each test specimen:
a) Identification mark,
b) Date of test,
c) Age of specimen,
d) Date of casting,
e) Weight of specimen,
f) dimensions of specimen,
g) Cross-sectional area,
h) Maximum load,
j) Compressive strength, and
k) Appearance of fractured faces of concrete and type of fracture, if these are unusual.
Step -8 Hot / Cold Weather Concreting Requirements
1) In hot weather, (temperature of surrounding higher than 40ºC) concrete shall be transported in deep
containers to reduce the loss of water due to evaporation and the same method for transport shall be
adopted in cold weather (temperature of the surrounding lower than 15ºC) to reduce heat loss.
2) In hot weather, work shall be restricted to the cooler parts of the day. The formwork shall be
continuously sprayed with cold water in advance of actual concreting. Excess water shall be removed
from inside of forms, just prior to the concrete placement.
3) The reinforcement and formwork, if metal forms are used, shall be protected from the effects of hot
winds and direct sunlight.
4) The concrete shall have a temperature not higher than 40ºC when placed. This shall be achieved by
making use of chilled mixing water, flaked ice or by spraying water on the coarse aggregate (pre-cooled
aggregates) or both, and if necessary, by covering the container in which the concrete is transported to
the site by wet Hessian cloth.
Step -9 Acceptance of completed work

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Inspection of concrete after removal of formwork and Corrective Measures:

1) On removal of formwork, the surface shall be examined by Engineer. The inspection shall be carried
out to check the finish of the concrete, deflections, bulges and other defects.
2) The corrective measures for the dimensional defects shall be taken in consultation with the structural
consultant.
3) If any structural cracks are observed, they shall be brought to the notice of the structural consultant
and shall be repaired at the earliest.
Acceptance of work as regards Structural stability:
1) In all cases 28 days cube strength shall be the basis for acceptance of concrete.
2) In case results of compressive strength of cubes show failure or low results than the acceptance
criteria, the same shall be immediately reported to the structural consultant for initiating further course
of action.
3) Structurally damaged members shall be brought to notice of Structural Consultant.
4) Certificate of Structural Consultant as regards safety of structure shall be obtained after each slab
construction.
5) Breaking of structural member shall generally be avoided unless specifically asked by the Structural
Consultant.
Step -10 Repair Work
1) Honeycombing, especially severe honeycombing shall not be patched up without showing the
conditions to the QA Engineer who would decide the remedy.
2) Honeycombs of mild and moderate nature, in the concrete, where the reinforcement inside is not
exposed, shall be repaired with use of approved non-shrink mortar mixed with bonding chemical. The
repaired patch of concrete shall be cured for 7 days or by using curing compound as recommended by
manufacturer.
3) For repair of honeycombs in concrete, where reinforcement is exposed, epoxy grout shall be used for
the repair work and cured for 7 days or by using curing compound as recommended by manufacturer.
4) Brands of repair material and chemicals shall be approved by QA/QC Department for use to repair
surfaces of damaged concrete.
5) Through shrinkage cracks shall be grouted with approved non-shrink grout, whereas minor shrinkage
cracks shall be filled with cement slurry.
6) If a structural member requires to be demolished in the opinion of Structural Consultant, the same
shall be enclosed by forms from all sides before demolishing and supported adequately.

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7) All repair works shall be carried out in accordance with the manufacturer’s recommendations as
regards the preparation of surface, cleaning, hacking, applying bonding agents, admixtures, polymer
mortars etc.
Step 11: Guidelines for Acceptance of Finished Product (RCC)
Type of Defect Tolerance / Acceptance
Visual
Visible offsets in column starters Not greater than 5 mm
Column offsets with beam Not greater than 5 mm
Column cap (column Topi) plumb Should not be out of plumb by 5 mm
Visible bulge in Column cap (column Topi) Not greater than 5 mm
Rebars exposed in columns No tolerance
Aggregates exposed in column Maximum 3% of Column Surface after DE
shuttering but needs repairing.
Instruction given for Breaking column To be followed
Difference in plumb of column in successive floors Not greater than 5 mm
Visible offsets in beam sides Not greater than 5 mm
Rebars exposed in beams No tolerance
Aggregates exposed in beams Maximum 3% of Beam Surface after DE
Difference in beam bottom alignment Not greater than 5 mm
Type of Defect Tolerance / Acceptance
Visual offsets in slabs Not greater than 5mm
Aggregates exposed in slabs Maximum 3% of Slab panel Surface after DE
Rebars exposed in slabs No tolerance
Measured
Bulge and right angle of columns, beams and lift 10 mm
pardi
Plumb of columns, beams and lift pardi 5 mm
Grid distance (face to face) for columns 5 mm

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Outer plumb of beams / columns 5 mm

Bottom level difference in slab soffit 10 mm (+/-) in 3 m length
Top level difference in slab finished level 10 mm (+/-) in 3 m length
NOTES: After removal of shuttering
1) Honeycombs should not be observed
2) No wooden pieces / debris should be observed embedded in RCC
3) Offsets should not be present
4) Deep pockets should not be observed beyond rebar in columns / beams.
For practical purpose Honeycombs should be recorded as:
1) Minor honeycomb – After removal of shuttering, minor aggregates exposed with slurry leakage.
2) Moderate honeycomb – After removal of shuttering, moderate aggregates exposed with slurry
leakage.
3) Severe honeycomb - After removal of shuttering, aggregates as well as steel bars are exposed
Guidelines for spacing “IN-PLACE” Cover Blocks
Bar Diameter Spacing centre to Approx. Nos. per Position of Cover
Nature of work
(mm) centre (mm) 100 sqft. Block
Slab / Raft Slab 8 600 25 Staggered in rows
10 600 25
12 600 25
16 750 16
20 750 16
Columns 16 At three locations
20  Bottom
25  Centre
28  And 2” below
top level
32
Pardi / RCC Wall 8 600 25 Both sides of the
10 600 25 shuttering tied to
the outer
12 750 16
reinforcement of
16 750 16 the pardi and

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20 850 12 staggered in rows

Beams 8 600 NA For bottom as
10 600 well as side
reinforcement,
12 600
spaced over total
16 600 area of shuttering
20 750 and staggered in
25 750 rows.
28 900
32 900
NOTES: 1. Strength of cover blocks shall be equal to the grade of concrete.

2. For proper compaction, cover blocks shall be properly vibrated to reduce permeability of cover block.
3. Plastic / PVC cover blocks can be used in place of concrete cover blocks by proper approval from QA
Department.
Guidelines for Spacing Of: “IN-PLACE” chairs for slab / Raft reinforcement
Diameter of the bar to be
Min. diameter chair Bar Position and Number of chairs
supported
10 mm 6 mm  Minimum 1 no. for every bent-up
12 mm 6 mm bar of the slab reinforcement
16 mm 8 mm  Distance from overhang portion of
bent up bar should be 100 mm
20 mm 8 mm and distance between chairs
25 mm 12 mm should not exceed 900 mm
28 mm 12 mm
NOTES:
 Above mentioned spacing and diameter of chair bars may be changed as per requirement at site
 Size of the chair may be increased to support more than one bar with greater chair bar diameter.
Records :

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ITP Reference No :
METHOD STATEMENT
FOR
MASONRY WORK

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MASONRY WORK
General:
There are various types of materials used for masonry works such as bricks, blocks (solid / hollow),
cellular light weight concrete blocks, fly ash lime bricks etc. The mortar used for above masonry
consisting of cement, sand natural as well as crushed, fly ash, water and admixtures. The details for the
above materials are as follows:
Cement:
For masonry works, following checks are important.
1) Cement shall be OPC 42.5N Grade and not more than 8 weeks old.
2) Cement shall be free from lumps.
Natural Sand:
Sieving of sand should be done for mortar for masonry. Gradation of sand for use in masonry mortars as
per SANS is given below for reference.
SIEVES Percentage passing by mass

4.75 mm 100
2.36 mm 90 to 100
1.18 mm 70 to 100
600 microns 40 to 100
300microns 5 to 70
150 microns 0 to 15
If grading of sand falls outside the specified limits as above, the required grading may be obtained by
screening and / or blending together natural sand and crushed sand having required size particles in
appropriate quantities.

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Silt content should not exceed 8 % by volume ( 3 % by weight ).

Fineness Modulus can vary from 1.5 to 2.5.
Washed / Crushed Sand:
For masonry works, following checks are important.
1) Fineness Modulus can vary from 1.5 to 2.5.
2) If grading of crushed sand falls outside the specified limits as above, the required grading may be
obtained by screening and / or blending together natural sand and crushed sand having required size
particles in appropriate quantities.
Water:
Water must meet the requirements of SANS and should be tested at a third-party laboratory to check
the compliance before use.
Specifications:
 Bricks:
In spite of various materials available for masonry works such as concrete blocks, stones, fly ash bricks
etc. traditional burnt clay bricks have their own importance in masonry works due to following
advantages.
 Durability
 Good for plaster / finishing works
 Light in weight compared with concrete blocks
 Good thermal insulation property.
Bricks shall be hand moulded or machine moulded, made from suitable soil and shall be free from
cracks, flaws and free lime. Bricks shall be well burnt, cherry red in colour, gives a ringing sound when
struck against each other. Bricks may have well defined frog of 10 mm to 20 mm depth and covering
about 15% of surface area as per relevant BIS. Bricks shall have smooth rectangular faces with sharp
corners and show uniformity in colour. Bricks used as partition walls shall confirm to minimum Class 3.5
as mentioned in SANS.
Bricks failing in dimensional analysis, especially in width parameter shall not be used for construction of
external walls to limit plaster thickness, avoid cracking and de-bonding of excessively thick plasters.
The inspection norms, acceptance criteria and frequency of test of bricks had been laid down in the
following table.
Sr. Description Mode of Inspection Acceptance Criteria Frequency
No.

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1 Dimensional Field Test: Every Truckload /

Analysis 20 bricks at random are chosen Consignment
and placed on a plane horizontal
surface
For 20 bricks lot:
Theoretical length Vs Actual < +/- 80 mm
length < +/- 40 mm
Theoretical width Vs Actual < +/- 40 mm
width
Theoretical height Vs Actual
height
For individual brick (out of 20
brick lot)
Max. length of Brick sample VS
Min length of Brick sample < 10 mm
Max. width of Brick sample VS

Min width of Brick sample < 5 mm
Max. height of Brick sample VS
Min height of Brick sample
< 5 mm
* All sides should be in right
angle and edges not broken.
2 Average Water External / Internal lab test Not more than 20% Once per source
absorption
3 Average wet External / Internal lab test Not less than 3.5 Once per source
crushing MPa
strength
4 Efflorescence External lab test Not more than Every 10000
Coverage ‘Moderate’ as per IS bricks or when
by visual source changes
observation

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 Concrete Blocks: (Solid and Hollow)

A) Raw materials and their inspection:
Terminology:
a) Concrete Block shall be applied to concrete masonry unit having any external dimension greater than
the dimension of an ordinary brick and shall be of such size and mass that it can be handled by one man.
Moreover, height of block shall not exceed either its length or six times its width. Concrete blocks shall
conform SANS.
b) Hollow Concrete Blocks: Concrete blocks having holes or cavities such that total solid material lies
between 50 – 75% of total volume of block, calculated by its external dimensions, shall be termed as
Hollow Concrete Blocks.
Both Solid and Hollow Concrete block shall be referred with respect to their external dimensions. Hollow
concrete block shall be of Grade A, Grade B or Grade C whereas Solid concrete blocks shall be of Grade
D as per SANS with the acceptance criteria as specified there in.
Visually, blocks shall be sound, have uniform texture and shall be free from cracks and other defects
which may impair its strength. The faces of concrete blocks shall be flat rectangular and opposite faces
shall be parallel as also all angles shall be 90o. Minor chipping resulting during handling shall be allowed.
Concrete blocks shall satisfy Dimensional Analysis Criteria, Block Density, Compressive Strength, Water
absorption test, drying shrinkage etc.
B) Acceptance Criteria:
Following procedure shall be adopted for acceptance of concrete block at site.
Readymade Concrete Blocks:
i) For the purpose of sampling, 20 blocks shall be chosen from every lot / consignment. (Consignment of
5000 blocks or part thereof of same grade and dimension shall be considered as a lot).
ii) Blocks selected, shall then be subjected to tests as described and acceptance of the blocks shall be as
per criteria mentioned therein.
iii) Concrete blocks shall bear identification mark of manufacturer as well as Grade of concrete.
iv) Concrete blocks over which plastering is required shall have rough textured faces.
Cast-in-situ Concrete Blocks:
i) Concrete used for making blocks shall not be richer than 1 part of cement by volume to 6 parts by
volume of combined aggregates.
ii) W/C ratio shall be strictly adhered to using electronically measuring device attached to mixing drum.

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iii) Web marking in hollow blocks shall be clearly indicative of good workable concrete.
iv) Blocks shall be properly compacted by vibro-compaction and finished by proper sizes without
breaking edges.
v) After de-moulding, concrete blocks shall be allowed to harden and then cured for a period of about 14
days by completely immersing in water or by covering with moist wet hessian cloth.
vi) Smooth concrete blocks which require plastering shall be given a rough texture on its faces with wire
brush, while concrete blocks are still green.
vii) After curing, concrete blocks shall be dried for a period of about 2 weeks, prior to their actual use.
Special checks on hollow concrete blocks:
Face shell thickness and thickness of webs of Hollow Concrete Blocks shall be checked as per following
table as per SANS
Sr. No. Nominal Block Width (mm) Face Shell Thickness (mm) Thickness of Web (mm)
1 100 or less 25 25
2 100 – 150 25 25
3 150 – 200 30 25
4 Over 200 35 30
 Cellular Light Weight Concrete Block
A) Raw materials and their inspection:
Visual observations: CLC blocks shall be referred with respect to their external dimensions. Visually,
blocks shall be sound, have uniform texture and shall be free from cracks and other defects which may
impair its strength. The faces of CLC blocks shall be flat and rectangular. Opposite faces shall be parallel
and all angles shall be 90o. Minor chipping up to 25 mm resulting during handling in 5% of blocks
inspected shall be allowed.
B) Acceptance criteria:
For the purpose of sampling, 20 blocks shall be chosen from every lot received through consignment /
cast on site and they shall be visually inspected (Consignment / casting lot of 10000 blocks or part
thereof same grade shall be considered as a lot).
a) Blocks selected, shall then be subjected to tests as described and acceptance of the blocks shall be as
per criteria mentioned in SANS.
b) Factory supplied CLC Blocks shall bear identification mark of manufacturer as well as crushing
strength in Mega Pascal (MPa) or N/mm2.

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Guidelines for inspection of Concrete Blocks (Solid and Hollow)

Sr.
Description Mode of Inspection Acceptance Criteria Frequency
No.
Dimensional Field Test: Every
Analysis 20 blocks at random are checked. Consignment
1 Theoretical Vs Actual Length < +/- 5 mm
Theoretical Vs Actual Width < +/- 3 mm
Theoretical Vs Actual Height < +/- 3 mm
Average Block > 1500 kg / cum (Hollow blocks,
Density (3 Field Test Load bearing)
2 blocks out of Every
1000 - 1500 kg/cum (Hollow
20) Consignment
blocks, non-load bearing)
> 1800 kg /cum (Solid blocks)
Average External / Internal lab test 10% by weight Every
Water Consignment
3 absorption (3
out of 20
blocks)
Average External / Internal lab test > 2.8 MPa (Hollow load Every
Compressive bearing individual) Consignment
Strength
> 3.5 MPa (Hollow load bearing
average)
>1.2 MPa (Hollow non load
4
bearing individual)
>1.5 MPa (Hollow non load
bearing average)
>4.0 MPa (Solid individual)
>5.0 MPa (Solid average)
5 Average MTC / External Lab test < 0.10 % Once in
Drying every 50000
Shrinkage blocks or
change of

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source
Visual Defects Field test Free from Minor cracks, Every
6 chipping in blocks not greater Consignment
than 25 mm in depth
Guidelines for Inspection of Non-Load Bearing CLC Blocks Grade 1 & Grade 2 Ref: SANS
Sr.
Description Mode of Inspection Acceptance Criteria Frequency
No.
1 Dimensional Field Test: Once in every
Analysis 12 blocks at random are 10000 blocks or
checked. change of
< +/- 5 mm source
Theoretical Vs Actual
< +/- 3 mm
Length
< +/- 3 mm
Width
Height
2 Average Block Internal Lab Test Not more than 1o00 kg /cum Once in every
Density (3 blocks Grade 1 & 2 10000 blocks or
out of 24) change of
source
3 Average External / Internal lab test Density Strength MPa Once in every
Compressive Kg/ cum G1 G2 10000 blocks or
Strength (6 out of change of
451-550 2 1.5
24 blocks) source
551-650 4 3
651-750 5 4
751-850 6 5
851-1000 7 6
4 Average Thermal MTC / External Lab test Density Thermal Conduct Once in every
Conductivity (3 out Kg/ cum W / mk 10000 blocks or
of 24 blocks) change of
451-550 0.21
source
551-650 0.24
651-750 0.30

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751-850 0.37
851-1000 0.42
5 Average Drying MTC / External Lab test < 0.05 % for Grade 1 blocks Once in every
Shrinkage (3 out of 10000 blocks or
< 0.10 % for Grade 2 blocks
24 blocks) change of
source
6 Visual Defects Field test Free from cracks, right angle Once in every
edges satisfactory, chipping in 10000 blocks or
(all 24 blocks) blocks not greater than 25 mm change of
in depth source
C) Nominal dimensions of CLC Blocks Ref: SANS:

Concrete block shall be referred to by its nominal dimensions. The term ‘nominal’ means that the
dimension includes the thickness of the mortar joint. Actual dimensions shall be 10 mm short of the
nominal dimensions (or 6 mm short in special cases where finer jointing is specified).
The nominal dimensions of the concrete block shall be as follows:
 Length: 400, 500 or 600mm
 Height: 200, 250 or 300 mm
 Width: 100, 150, 200 or 250 mm
In addition, block shall be manufactured in half lengths of 200,250 or 300 mm to correspond to the full
lengths. The nominal dimensions of the units are so designed that taking account of the thickness of
mortar joints, they will produce wall lengths and heights which will conform to the principles of modular
co-ordination. Blocks of sizes other than those specified above may also be used.
TOOLS:
A. Trowels, Line Dori, Level Tubes, Plumb Bobs, Measuring Tape, Spirit Levels, Aluminium Straight
Edge, Right Angles.
B. Chipping tools, Mason Trowel, Mason hammer, Levelling thread, Mason Brushes, Mortar Boxes.
Procedure to be followed for Brick / Block Masonry:

Pre-Masonry Checks:
1) Before starting masonry, it should be ensured that all electrical conduiting works should be complete
through beams.

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2) Cleaning of slab surface should be done where masonry work to be carried out and centreline of brick
/ block work should be marked on the slab. Dimensional checking should be done for room dimensions
and diagonals.
3) Soaking of bricks in stack should be done by immersing in water or by sprinkling with water on the
previous day of laying. The blocks shall be slightly moistened from all sides by little sprinkling of water.
Excessive wetting of blocks shall be avoided.
4) Only required nos. of bricks / blocks should be carried to the work place to carry out the activity.
5) Saw dust / sand bags should be stacked over / around beam and column locations and unloading of
bricks / blocks at work place should be done over it to avoid damages due to unloading.
6) Stacking of bricks should be done near beams and column locations and maximum 100 bricks /
stacking of blocks weighing not more than 300Kg should be stacked over an area of 1 sq. m.
7) Concrete surface should be cleaned of all nails, embedded wooden pieces, etc. using wire brush
before layout for masonry.
8) Adequate hacking of surface should be done to concrete surface (base slab as well as adjacent column
surface). An approved bonding agent (e.g. Hacked plast) may be applied to concrete surface in place of
hacking for bonding.
9) Sieving of sand should be done for mortar for masonry. Gradation of sand for use in masonry mortars
as per SANS is given for reference. If grading of sand falls outside the specified limits as above, the
required grading may be obtained by screening and / or blending together natural sand and crushed
sand having required size particles in appropriate quantities.
10) Line out for masonry work should be done before starting actual laying of masonry. First, slab
surface should be cleaned and applied with cement slurry and a layer of rich mortar. Over this, bricks
shall be laid. Checks for dimensions and right angle should be done as per drawing. Discrepancies in
dimensions shall be adjusted on site in consultation with site engineer to finalize lineout.
11) Scaffolding: - Scaffolding shall be double and shall be erected with steel sections or pipes of
adequate strength so as to be safe for construction operations. The contractor shall take all measures to
ensure the safety of the work and working people. Proper scaffolding shall be provided to allow easy
approach to every part of the work. Overhead work shall not be allowed. Making holes of any kind for
the purpose of supporting the scaffolding shall not be permitted. The scaffolding shall be sound and
strong to withstand all loads likely to come upon it.
During Masonry Checks:
1) Mortar for masonry should be mixed in desired proportions in M. S trays only. In absence of M. S
trays, mortar should be prepared in sunk of toilets or by creating a circular bund of bricks / blocks. This

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should be done to avoid loss of cement slurry while preparing mortar. Batching of sand should be strictly
done by pharma’s (measuring boxes).
2) Replacement of Ordinary Portland Cement by fly ash up to a percentage as approved by quality
department with respect to Cement strength/properties is recommended and may be done in mortars
for which mixing should be done in mechanical mixers only and the mortar shall be brought to work
place by wheel barrows and unloading should be done in M. S trays / sunk slabs / bunds at work place.
3) Crushed sand can be used individually or blending it with natural sand as per graduation requirement.
4) It is essential that proper water cement ratio is maintained in mix. After mixing, mortar should not
show excess bleeding water. Admixtures, if recommended, should be added in proper dosages.
5) First layer of brick work should be laid as per layout marked with position of frog upwards and first
layer of block work with a mortar of one grade higher. If necessary, first layer of block shall be laid with
concrete, so that all the subsequent layers can be laid in full block height and no cutting of blocks is
required while laying top course below beams. Bricks / blocks laid on top should be tamped for proper
bondage. Level adjustment should be done in the thickness of mortar bed so that top of laid course is in
perfect level. Spirit level should be used for the same.
6) Subsequent layers of bricks / blocks should then be laid over first layers, care being taken so that each
layer is truly horizontal and joint thickness is not more than 15mm horizontal as well as vertical.
7) Use of mortar should be made within 90 minutes of preparation and any mortar which has set should
not be mixed with fresh mortar. Also, it essential that water should not be added to increase workability
since it reduces strength of mortar. Instead, use of plasticizer is recommended. While preparing mortar,
cement and sand shall first be dry mixed and then water is to be added in appropriate quantity.
8) Mortar should be dashed on column surfaces as work progresses for proper adhesion. Gap of 20 mm
shall be left between column surface and masonry. Use of trowel for filling gap between column surface
and masonry works should be avoided. Joints between column surface and masonry shall be filled with
rich mortar and then packed with 20 mm metal.
9) In a day’s work, brick/block work should not be constructed more than 1.2m height for 6”/9” walls
and 0.9 m height for 4” walls at the most. At the end of the day, joints (horizontal & vertical) should be
raked to a depth of 10 mm with the help of raking needle. Such brick/block work should be watered
within 12 hours of construction. Minimum curing period recommended is 7-10 days depending on type
of cement and climatic conditions.
10) Special precaution should be taken at the junction of 9” to 4” wall by properly interlocking bricks and
at the junction of brick and block walls.
11) Next day an RCC (M 15) band of 3” / 4” in height should be constructed over the brick / block work
(4” or lesser) laid earlier. This imparts additional strength to the brick / block work. Such bands need not

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be provided for 6” and higher thickness of walls for normal room heights up to 3 m. It is recommended
to put 8 mm bars (2 nos.) within RCC bands and anchored properly in main walls / columns.
12) Local lintels should be cast before fixing door frames as per drawing with sufficient bearing on
masonry walls. Recommended bearing of lintels on masonry is 6” and anchoring of lintels to columns
should be done by drilling holes (minimum 4” deep inside columns) and thereafter filling the holes
inserting projecting bars from lintels into it and entire holes should be filled with epoxy based non-shrink
grout for proper bondage. Lintel bottom level should be checked accurately from finished floor level.
Shuttering, if cast on site for lintels, lofts and chajjas shall not be erected within 3 days of construction of
masonry.
13) In Hollow Concrete Block work, care shall be taken so that mortar doesn’t get filled in the cavities of
blocks to avoid unnecessary wastage of mortar.
14) It is important that in both Solid as well as Hollow Concrete Block Masonry works following is
attended to:
a) Top course at sill level and jambs of openings as well as top course touching beam or slab soffits are
constructed using Solid Blocks or with Hollow Blocks with cavities filled with M10 concrete.
b) For conducting through hollow blocks, the cores shall be filled with mortar at the location of
conducting for the purpose of chasing to required depth.
15) Fixing of sub frame is strongly recommended.
16) Bottom edge of brick / block work should be raked and 15 mm portion away from walls should be
filled with lean mortar for expansion of tiles.
17) Door frames should be preferably be fixed while masonry is being constructed, to avoid gaps
between door frame and masonry surface.
18) It is recommended to use very heavy holdfasts for door frames and hence from practical point of
view recommendation for holdfast are; 4 nos. for external door and 3 nos. for internal doors each.
Holdfast should be of MS (Galvanized or painted with red oxide), 350 mm long 40 mm wide and 2 mm
thick and fully embedded in concrete / screwed to columns.
19) When door frames are to be fixed after masonry construction, temporary brick pieces should be
filled to the entire length of holdfasts and to the height equal to two courses of bricks at the positions of
holdfasts during construction of masonry and while fixing door frames, holdfasts should be anchored
into required positions by filling the surrounding gap by 1:2:4 concrete using 10 mm downgraded coarse
aggregate. Recommended positions of holdfasts are 300 mm each from top and bottom and third at
centre. Fixing of holdfasts to columns should be done by drilling and nailing alternately on either side.
Gap between door frames and masonry surface should be filled with rich mortar with fibres or non-
shrink mortar.

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20) If door frames are fixed along with masonry construction, it is strongly recommended that door
frames fixing should be done by taking level pads (spots) of plaster on masonry walls whenever door
frame is flush with plaster. Door frames shall be fixed so that it is parallel to room dimensions.
21) Door frames should be checked for any cracks, bends, plainness, depths of rebates as per drawing
and door frames showing deviations beyond repairs should not be used. Minor bends in door frames
should be corrected out by inserting wedges.
22) It is must that all openings other than doors should be provided with PCC bands.
23) One more level correction should be carried out at the top of PCC / RCC band.
24) Above PCC / RCC band, masonry courses are laid in the similar way as explained earlier. However,
masonry work should not continue up to soffits level of beams above. The reason for this being,
shrinkage which occurs within the masonry already constructed. So, it is recommended to leave a gap of
one layer of bricks with 25 mm gap below beam bottom while constructing masonry for the same.
25) After a gap of 7 days, top most layer of masonry should be laid using non-shrink mortar as a filler
material between masonry and RCC beam bottom to avoid any subsequent gap formation due to
shrinkage. Also 20 mm metal packing should be done within the joint between masonry top and beam
bottom.
26) For masonry works, which requires stoppage for any reason whatsoever, a stepped joint at
approximately 45º should be provided as a horizontal joint for proper bondage of bricks later. For cross
wall connection bricks should be left projecting at every third course in the main wall for joining to cross
wall later.
27) It is recommended that for 4” and less partition walls, electrical switch boxes should not be placed
back-to-back since while making grooves from both sides for embedded electrical conduiting, the
masonry wall gets weakened.
28) Care shall be taken to see to it that vertical mortar joints in successive brick layers are staggered.
29) For box type aesthetic features, which are closed from outside, a small opening in masonry shall be
kept during construction. Inside face of box shall be plastered and bottom portion shall be applied with
water proof cement sand coat and finished with rounding. The base coat shall be given slope outwards
and provided with minimum two spouts to drain off water. Mortar droppings within the box shall be
removed from the openings provided.
30) During masonry work, strong supervision is required for achieving good workmanship and quality
work.
Post Masonry Checks:
1) Date of construction (DOC) should be marked on masonry to monitor curing. Curing shall be carried
out by wetting the brick masonry for 7-10 days depending on type of cement and climatic conditions. In

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hot weather, curing shall commence within 12 hrs. of construction of masonry. Care should be taken
that the masonry surface should remain moist throughout the period of curing.
2) It is recommended that chases in masonry should be made using round wheel cutter with light
chiselling so that masonry works is not damaged. Also chases in masonry lesser than 6” thick should be
done after plastering work is complete.
3) Depth of chases should be only 5 mm more than diameter of electrical conduits to be embedded.
Excessive chasing weakens the masonry. No chasing shall be done in RCC structural member.
4) After conduits are put in chases, chases are rendered with non-shrink grout with fibres and chicken
mesh is fixed over it.
5) In case of any major defects such as major differences in level, plumb of masonry, dismantling shall be
carried out as per instructions from QA Department
Tolerances:
Following checks should be given once brick masonry construction is over:
1) Horizontal / Vertical joint thickness should be uniform, truly horizontal or truly vertical and not more
than 15 mm thick.
2) Tolerance limit for coarse level should be 10 mm maximum.
3) Raking of joints – minimum 10 mm deep.
4) Checking plumb of walls:
 Non plumb face of masonry should not be out of plumb of more than 10 mm.
 Plumb face of masonry should not be out of plumb by more than 5 mm.
(IS specifies maximum 6 mm tolerance for a storey of height 3 m and 12.5 mm for entire height of
building more than single storied building)
5) Checking room dimension: Tolerance kept for diagonal distance is 10 mm.
6) Checking qualities of bricks on masonry walls: Over burnt bricks should be limited to 10%. Bricks
showing high variation in dimensions should be limited to only 10% of walls under observation.
Records :
ITP Reference No

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INTERNAL PLASTERING WORKS

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INTERNAL PLASTERING WORK

General:
Cement:
For internal plastering, following checks are important.
1) Cement shall be OPC 42.5N Grade or PPC and not more than 8 weeks old.
Natural Sand:
Sieving of sand should be done for mortar for plastering. Gradation of sand for use in plaster mortar as
per IS 1542 is given below for reference.
SIEVES Percentage passing by mass

10 mm 100
4.75 mm 95 to 100
2.36 mm 95 to 100
1.18 mm 90 to 100
300microns 20 to 65
150 microns 0 to 15
Silt content should not exceed 8 % by volume (3% by weight) and fineness modulus may vary from 1.2 to
2.2. However, it is preferable to have minimum Fineness Modulus around 1.5.
Crushed / Washed Sand:

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For washed / crushed sand following checks are important:

1) Fineness Modulus can vary from 1.2 to 2.2, however it is preferably to have minimum Fineness
Modulus around 1.4.
particles appropriate quantities.
Fly ash:
For internal plaster works, following checks are important:
1) Sources of fly ash must be standardized as per test reports and fly ash must meet the requirements of
SANS. Further retention on 45-micron sieve after wet sieving should be less than 20%.
2) Fly ash should be free from lumps.
3) If mortar mix design is made using fly ash, mechanical mixer shall be used while preparing mortar.
Water:
Construction water must meet the requirements of SANS.
TOOLS:
A. Trowels, Line Dori, Level Tubes, Plumb Bobs, Measuring Tape, Spirit Levels, Aluminium
Straight Edge, Right Angles.
B. Chipping tools, Mason Trowel, Mason hammer, Levelling thread, Mason Brushes, Mortar
Boxes.
Procedures to be followed for Internal Plastering Work:
 Pre-Plastering Checks.
1) It is recommended to carry out external plastering before internal plastering to prevent rapid drying
and shrinkage of internal plastered surfaces.
2) Minimum gap of 7 days shall be maintained between completion of brick masonry and
commencement of internal plaster application.
3) For application of cement sand plaster, thorough wetting of masonry should be done 2 days before
commencement of plastering. The day prior to plastering, masonry surface shall be left to attain
Saturated Surface Dry (SSD) condition.
4) Proper scaffolding shall be provided to allow easy approach to every part of the work, take all
measures to ensure the safety of the work and working people. In no case, holes in masonry should be
done for supporting scaffolding.

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5) Level pads of size not less than 2” x 2” shall be made on the walls and if required on ceiling also to
serve as finished reference level surface. The distance between level pads shall not exceed 6’ in any
direction so that their surface alignment can be checked with the help of aluminium straight edge.
6) Level pads shall also be checked for vertical alignment with the help of plumb bob, for right angle with
the help of right angle and for diagonal dimension of room with the help of tape.
7) At place of work where sufficient natural daylight is not available, artificial light shall be made
available.
8) In case of level differences in adjoining surfaces, the same shall be made up before fixing of chicken
mesh / fibre mesh.
9) Chicken wire mesh shall be fixed at the joints of BBM and concrete. Chicken wire mesh shall be 20
gauge, with 12 mm hexagonal holes and minimum 6” wide in the form of strip.
10) Chicken mesh after stretching shall be fixed at 9” intervals by drilling/punching holes in masonry and
concrete and then nailing with metal washers. Minimum overlap for chicken mesh shall be 4”.
11) Instead of chicken mesh, fibre mesh can be used. Fibre mesh shall be stretched over the joints and
fixed to walls with the help of mortar spots at every 9” interval. Joints of brick /block & RCC junction
shall be applied with non-shrink mortar e.g. CNS 50 or equivalent.
12) Surface preparation
 All the nails, binding wire, concrete projections and wooden piece shall be removed from concrete
surface and brick masonry.
 All the dust, oil spots, and green algae, if any, shall be cleaned from concrete and brick masonry
surface with the help of wire brush.
13) It is recommended that all concrete surfaces where plaster is to be applied shall be applied with
bonding agent. Bonding agents shall be applied as per instructions of manufacturer. If bonding agent is
used, hacking of concrete surface shall be avoided.
14) Concrete surface should be roughened for proper bonding. Hacking should be done @ 1” c/c.
(Minimum 60 to 65 hacks per Sq. ft.)
15) All electrical chases shall be properly rendered with non-shrink grout and application of chicken /
fibre mesh over it and cured properly for 7 days before starting any type of plaster or curing compound
can be applied for the same.
16) All the conduit drops shall be checked and concealed with plaster. All the ceiling points and wall
points shall be checked for level and dimensions as per drawing or as per client’s requirement if any.
17) It shall be ensured that all electrical boxes are protected with plastic sheet packing before plaster.
18) Wooden / natural stone frame used for doors / windows should be protected before plastering.

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19) It shall be ensured that all plumbing points are in proper location, line and level as per drawing. All
plumbing chases shall be properly rendered with non-shrink grout and application of chicken / fibre
mesh over it and cured properly for 7 days before starting any type of plaster.
 During Plastering Checks:
Cement Sand Plaster
1) Mortar for plaster shall have minimum strength 3.5 MPa. For this 7.07 cm cubes shall be casted of
cement sand mortar and shall be tested after well curing for 28 days.
2) Cement sand mortar shall be used as specified and it is recommended to carry out batching of sand
by weight (batching if mix design for mortar is made)
3) In case, volume batching is to be done, calibrated boxes (pharma’s) of required correct sizes shall be
used. It is recommended to apply 1:4 mortar for side wall and 1:3 mortar for ceiling in the absence of
any specification. PPC or OPC-Fly ash combination is recommended, since reduced water demand and
reduced heat of hydration reduces shrinkage and thermal cracks respectively. Also, PPC or OPC-Fly ash
combination has better resistance against chemical and sulphate attack.
4) Water cement ratio shall be as per mix design (If mix design is available) or such as to obtain mortar
mix of optimum workable consistency.
5) Mortar required for Plaster work shall preferably be mixed in half bag or full bag mechanical mixer
and shall be carried out to required floor with the help of hoist and wheel barrows and unloaded in MS
tray/bund and thereafter it shall be carted to actual work place.
6) While preparing mortar in mixer, cement and sand shall first be dry mixed and then water is added to
it in appropriate quantity. Wet mix shall then be mixed thoroughly in mixer for a minimum period of 3
minutes. Fibre of 6mm length shall be used as specified by Q. A. Department. Plasticizers of approved
make may be used as specified.
7) For small works, mortar can be made by hand mixing in MS tray / sunk / bunds. After dry mixing, wet
mixing by hand shall be carried out for a period of at least 5 minutes.
8) The mortar mixed shall be utilized within 90 minutes of preparation and the same shall be used
before recommended setting time of cement mortar, if retarders are used.
9) While applying plaster on walls, empty cement bags shall be placed on floor near walls and
rebounded mortar fallen on bags shall be put back into mixed mortar before it sets and 10% additional
cement should be added in that mix and remixing should be done before its use.

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10) Use of dry cement shall be limited to finishing of edges only.

11) For internal plaster, average thickness of plaster shall not be less than 12 mm and not more than
15mm. The plaster above 15 mm thickness shall be done in 2 coats. Proper roughening to first coat shall
be done before application of second coat for proper bonding and shall be cured for at least 3 days.
Bonding chemicals can be used between the two coats for proper bonding.
12) Proper checking and supervision for plumb, line, right angle, measurement of openings after
application of plaster should be done by site supervisor / engineer.
13) Thickness above 20 mm, if required shall not be built up in single operation. Thickness will be built
up gradually using a combination of chicken mesh, fibre mesh, etc.
14) Electrical switch boxes shall be perfectly in line with plaster.
 Post Plastering Checks:
Cement Sand Plaster:
1) After plastering work is complete, neeru / sanla shall be applied on plastered surface within 2 hours
till the plaster is green and mason shall trowel the neeru / sanla surface to get smooth finish. Thickness
of neeru shall not be greater than 1.5mm and neeru shall be cured.
2) It is recommended that 5 mm deep grooves shall be made (to limit the shrinkage cracks) on the
finished neeru / sanla surfaces. Such grooves shall be spaced at 5’ both horizontally and vertically. After
a period of 4 weeks, these grooves shall be filled with plaster of paris to ensure a uniform surface. It is
applicable for back coats also.
3) Window frames, sills, door frames, electric switch boxes, fan boxes, taps, railings, plumbing fittings,
glass etc. shall be cleaned immediately.
4) Wherever wall tiling is required, roughening of plastered surfaces shall be carried out for better
bonding of tiles. In such a case, no application of neeru / sanla / POP / gypsum shall be made on the
plastered surfaces.
5) Plaster above the floor slab shall be cut in level to a height equal to height of skirting for fixing skirting
tiles.
6) In toilets, plaster shall be cut at 300 mm above FFL to accommodate base coat for water proofing.
7) Date of plastering shall be clearly marked on the plastered surfaces to monitor curing process.

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8) Curing shall be done so as to keep plastered surface continuously wet for a period of 7-10 days
depending on type of cement and climatic conditions.
9) Curing shall be done carefully, by gently application of water on top of wall surface, so that water rolls
down smoothly over plastered surface. Spraying of water jet with high pressure for curing shall be
avoided since it will peel off the neeru / sanla.
Tolerances allowed in Internal Plastering Work:
Type of Defect Tolerance
Plumb of pillars / columns 2 mm
Difference in right angle measured by 3-4- 5 3mm in 5’ length
method
Room dimensions (Length / width) 20 mm
Undulations in ceiling / wall surfaces Nil
Jamb sizes 3 mm
Non-uniformity in wall plaster Nil
Opening sizes (width / height) 5 mm
Defects in finishing of edges, offsets, corners, Nil
jambs and openings
Window / Opening sill finishing As per drawing
Visible cracks in plaster Nil
Delamination in plaster Nil
Records :
ITP Reference No :

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EXTERNAL PLASTERING WORK

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EXTERNAL PLASTERING WORK
General:
Cement:
For external plastering, following checks are important.
1) Cement shall be OPC 42.5N Grade or PPC and not more than 8 weeks old.
Natural Sand:
Sieving of sand should be done for mortar of plasters. Gradation of sand for use in plaster mortar as per
IS 1542 is given below for reference.
IS SIEVES Percentage passing by mass

10 mm 100
4.75 mm 95 to 100
2.36 mm 95 to 100
1.18 mm 90 to 100
300microns 20 to 65
150 microns 0 to 15
Silt content should not exceed 8 % by volume (3% by weight) and fineness modulus may vary from 1.2 to
2.2. However, it is preferable to have minimum Fineness Modulus around 1.5.
Crushed Sand:
For external plastering, following checks are important:

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1) Fineness Modulus can vary between 1.2 to 2.2. However, it is preferably to have minimum FM around
1.4.
particles in appropriate quantities.
Water:
Water must meet the requirements of IS 456:2000 and should be tested at a third-party laboratory to
check the compliance before use.
Admixtures:
For admixture following checks are important
 Brand and type of admixtures must be approved & standardized
 Density and chloride content should be checked before approval.
 Revalidation of mix design shall be done in case of any change in brand or type of admixture.
TOOLS:
A. Trowels, Line Dori, Level Tubes, Plumb Bobs, Measuring Tape, Spirit Levels, Aluminium Straight
Edge, Right Angles.
B. Chipping tools, Mason Trowel, Mason hammer, Levelling thread, Mason Brushes, Mortar Boxes.
Procedures to be followed for External Plastering Work:
Pre-Plaster Checks:
1) Minimum gap of 7 days shall be maintained between brick masonry and external plaster.
2) Sequence of plastering shall be decided in advance. Joints of plaster shall be kept on centre of RCC
members such as beams / columns.
3) It shall be ensured that scaffolding material to be used for the plastering should preferably be double
scaffolding. H- Frames or equivalent is recommended for the same. Both steel scaffolding as well as
wooden scaffolding is applicable up to 12 to 15 storey height. For larger heights, scaffolding shall be
designed from the designer and the same shall be used.

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4) No holes shall be made in masonry for supporting scaffolding.

5) Bulges from concrete surfaces on external beams shall be chipped of so as to bring entire masonry
surface as well as outer surface of members in one line.
6) Joints between masonry and concrete members shall be filled with non-shrink mortar e.g. CNS – 50 or
equivalent or rich cement sand mortar in proportion 1:3 with fibre (polypropylene/ polyethylene) added
to it, 2 days in advance of starting of plastering and then cured for next 2 days till external plastering
work starts.
7) Curtain cloths or plastic sheets may be provided on external sides to prevent rapid drying and
shrinkage cracks of plastered surfaces due to wind or sunlight.
8) Pegs are driven diagonally at the corner edges on each floor starting from the top most floor of the
plastering area and line dori shall be fixed on pegs keeping it fully stretched.
9) Similar line dori stretched over entire surface at 6’ distance apart horizontally by driving pegs at every
floor. Line dories shall also be stretched horizontally at 6’ distance apart vertically to form a grid.
10) In addition, line dories also stretched horizontally as well as vertically along the sills, soffits and
jambs of openings, windows, ventilators, chajjas, and any projections kept for architectural effects,
11) Level pads of size not less than 2”X2” in size at 6’ c/c (i.e. at every vertical line dori.) both
horizontally and vertically shall be made on the wall to serve as reference level surface for base coat.
Levels pad shall be checked for plumb and right angles.
12) Drain spout in toilet and sunk shall be fixed.
13) Plumbing pipe holes shall be made in masonry, diameter of hole being 1” more than the pipe
diameter all round.
14) All terrace outlets (bends) as well as other plumbing outlets shall be placed within the holes, and
holes shall be renders with non-shrink grout.
15) Chicken mesh /fibre mesh /expanding metal shall be applied on joints of Brick / Block Masonry and
concrete. Chicken wire mesh shall be of 20 gauges, with 12mm hexagonal holes and minimum 6” wide in
the form of strip, Chicken mesh after stretching shall be fixed at 9” intervals by drilling / punching holes
in masonry and concrete and then nailing with metal washers. Minimum overlap for chicken mesh shall
be 4”
16) Surface Preparation
 All the nails, binding wire, concrete projections, and wooden pieces shall be removed from concrete
surface and brick masonry.
 All the dust, oily spots, and green algae, if any, shall be cleaned from concrete and brick masonry
surface using wire brush.

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17) RCC / PCC coping for all sills and parapet tops shall be completed before commencement of external
plaster.
18) Masonry chiselling for electrical conduits or any other purpose shall be sealed with non-shrink
material with chicken mesh fixed over it, well before plastering of the surface.
19) The brick masonry shall be wetted thoroughly from outside on the day prior to day of application of
external plaster so that masonry surface is moist at the time of external plaster.
During Plaster Checks:

1) Mortar for plaster shall have minimum strength 3.5 MPa.
2) Cement sand mortar shall be used as specified and it is recommended to carry out batching of sand
by weight as per mix design.
3) In case volume batching is adopted, calibrated boxes of required correct sizes shall be used. Batching
shall be done as per recommended proportions in mix design.
4) Mortar required for plaster work shall be mixed in half bag or full bag mechanical mixers only.
5) While preparing mortar mix, cement, fly ash and sand shall first be dry mixed and then water is added
to it in appropriate quantity. Wet mix shall then be mixed thoroughly in mixer for a minimum period of 3
minutes. Fibre, if added in mortar shall be well separated by hand before putting them in rotating drum.
6) Water cement ratio shall be such as to obtain mortar mix of optimum workable consistency.
7) Water-proofing compound shall be added to mortar in adequate quantity as recommended by water-
proofing compound manufacturer. If water-proofing compound is in powder form, the same shall be
added to mortar during dry mixing of mortar and if in liquid form, the same shall be added to water
during wet mixing of mortar.
8) Mortar shall be used before initial setting time of mortar which is approximately 90 minutes.90utes of
9) External plaster shall be applied in two coats. Thickness of first coat shall not exceed 15 mm.
10) Empty cement bags / plastic sheets shall be kept on ground near the face of building and rebound
mortar collected on bags shall be poured in the mixer for reuse by adding 10 present extra cement. The
entire process shall not exceed 90 minutes.
11) In no case, joint of external plaster shall be kept on parapet wall, since that joint is highly susceptible
for seepage of rain water through parapet wall and ultimately to the rooms below. Parapet top plaster
shall continue at least 1’ inside the terrace.

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12) Thickness of plaster on parapet top shall not exceed 20 mm and plaster top shall be given slope 15
mm inside to drain off rainwater inside the terrace.
13) First coat of plaster shall be sufficiently roughened for bonding of second coat over it.
14) First coat shall then be cured for minimum 3 days to maximum 5 days and then finishing coat shall
be applied over first coat.
15) If the time gap between application of first coat and second coat exceeds 5 days, cement slurry shall
be applied over first coat before applying second coat. Instead, bonding agent as approved by QA/QC
Department can be applied for the same.
16) Grills, wherever provided, shall be fixed prior to application of second coat.
17) Bonding agent shall be applied to horizontal joints of first coat and finishing coat for proper
bondage. It prevents seepage of rainwater through horizontal joints. Horizontal joint as well as vertical
joint should be strictly kept on RCC members.
18) Thickness of second coat shall not exceed 8 mm and the same shall be finished as per requirement.
19) Grooves, if any, shall be of uniform depth and width throughout.
20) Finishing coat shall be applied in such a way that all vertical lines of windows, balconies, common
dividing walls shall match at all levels. Also sill and soffit levels of openings / windows / ventilators at any
floor shall be in one line.
21) Window reveals (external horizontal portion of window sill) shall be given outward slope to drain out
the rain water.
22) Drip moulds (Pani Patti) shall be provided to all the chajjas as well as projections. Pani Patti shall be
at 5 mm thickness and 35 mm in width or as per details given in the drawing.
23) Chajjas shall project minimum 6” beyond the window openings on both sides. If the drawing does
not show such projections, then such requirement shall be posed before the concerned architect and
work shall proceed with his suggestions or alterations.
24) Chajjas top plaster shall be rounded to merge inside the external plaster to prevent ingress of rain
water providing cut patti or as specified on drawing.
25) All external ornamental features shall show equal offsets, line, level, right angles etc.
26) In exceptional cases, where extra thickness of plaster is required (2” to 3”), the same shall be applied
in 2 to 3 layers, with proper anchoring by nails / chicken mesh / expanded metal etc.

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Post Plaster Checks:

1) Wherever tiling is to be done at a later stage, roughening of plastered surfaces shall be carried out for
better bonding of tiles.
2) Window frames, sills, door frames, electric switch boxes, taps, plumbing fittings, glass etc. shall be
cleaned immediately.
3) Date of plastering shall be clearly marked on the plastered surfaces to monitor curing period.
4) Curing of final coat shall be done, so as to keep plastered surfaces continuously wet for a period of 7-
10 days depending on type of cement and climatic conditions.
Value added Parameters / Cost affecting Parameter:
1) Pure sand bags or equivalent can be used in place of river sand. It has advantages over river sand such
as weigh batching and volume batching can be done as required. Also graded sand will give less wastage
and easy storage & stacking can be done as required. The mix proportion with graded sand
recommended by manufacturer is (1:6) which is cost effective as compared with river sand.
2) Cement mortar in river sand is highly recommended to be used for the first coat (1:6) and richer
mortar for second coat (1:4).
3) The cement mortar mix used in plastering of duct (wall having plumbing/drainage pipe lines) should
be (1:4) for first coat as well as second coat and water proofing admixture is highly recommended for
the same.
4) Fibre are preferred to be used in first coat to reduce the rebound losses, shrinkage and prevent
development of crack formation over plastered surface.
5) Water proofing compounds used in plaster works will reduce permeability and give waterproof coat
over plaster surface. It is very essential especially in case of dead walls and long walls with lesser
openings.
6) Liquid polymer modified mortar can be used for plasters. It has added advantages such as enhanced
cohesion & adhesion, water repellence and strength. It reduces the rebound loss and increase the rate
of application of the plaster. It reduces the requirement of water for curing. It also reduces the time the
application of external plaster if second coat applied as soon as the first coat set. That means both the
coats can be done in same day and cured simultaneously.
7) It is recommended to use bonding agent to all joints of plasters (horizontal or vertical) to avoid
leakages through joints in future.

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8) Sponge finish plasters are cost effective but uniformity in texture will not be maintained whereas
gudgudi coat finish over plaster is comparatively costly but it gives uniformity in texture and has better
resistance to weathering effect.
9) It is recommended to carry out external plastering before internal plastering to prevent rapid drying
and shrinkage of internal plastered surfaces.
10) It is essential to provide curtain cloths (hessian cloth curtain or plastic sheets curtain) on external
sides to prevent rapid drying of plastered surfaces due to wind and sunlight.
Tolerances: Refer QA card for external plaster.
Type of Defect ( By visual Observation ) Tolerance

Finishing and visible defects in plumb /right angles Nil
(Horizontal/Vertical)/edges/offsets/jambs
Undulations on wall surfaces Nil
Cracks at masonry and concrete joints and on Nil
parapet top
Visible difference in level of parapet top Nil
Difference in level of grooves Nil
Efflorescence Minor
Top surface of cornice/chajjas Made Round
Edges (vertical and horizontal) of openings / In perfect line for each floor when viewed
windows / ornamental features from outside
Windows / ornamental features As per drawing
Inspection Record :
Reference Documents
ITP Reference No :

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FALSE CEILING (GYPSUM BOARD)

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GYPSUM WORKS
1. Objective:
This work procedure enumerates the scope of Gypsum work to be executed in the buildings as
specified in the approved drawings and at places when instructed by the Engineer-in-charge as per
approved specifications.
2. Applicability:
This procedure is applicable to the Gypsum work for Main & Substation Buildings & relevant
structures.
3. Reference Document:
a. Tender Specifications
b. Drawings
c. Manufacture’s Specifications
d. Client preferred Standard Codes
4. Equipment’s:
1. Related “Good for Construction” drawings
2. Plumb bob
3. Spirit levels 3m
4. Right angle
5. Measuring tape
5. Material:
1. 6.4 mm Rhino gypsum plaster board or similar any brand.
2. Rhino 75mm cornices & nailed.
3. H-type pressed steel jointing strips horizontal ceilings.
4. 380 x 380 mm sawn softwood brandering.
Procedure:
Material handling and stacking
Generally, two men will be required and this will reduce the risk of damage to the boards. When off-
loading manually boards must always be carried on edge.
The boards should always be stored in a dry & covered place, sheltered from rain. They should be

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supported on wooden battens, to avoid dampness from floors. These battens should not be more
than 45 CMS apart on a flat surface. Gypsum board should never be stacked on edge for long periods
as this can cause deformation.
Cutting
Gypsum boards can easily be cut either longitudinally or transversely. A cut should be made in the
face side of the board by means of a retractable knife. A line may be ruled prior to cutting, or with
practice. The rule may be drawn down the board at the required distance from the edge whilst the
board is scored with a knife at the end of the rule. The board should then be pressed with both hands
and the gypsum core will break in line with the cut in the side face. The board should then be turned
over and the other side paper be cut with the knife.
Sawing
Gypsum board may be cut using a normal saw. A fret saw or an electric tool may also be used for
cutting of curves. When large quantities of board are to be cut, the use of a circular handsaw is
advisable.
Making holes/cut outs
Electrical or manual carpenters’ tools may be used for making cut outs. Drills should be used when
making holes for electrical installations. For holes of a diameter less than 50mm a high-speed still drill
gives a better result.
Planning
The edges of the board can be pared off using a plane. A file may also be used to level off any
irregularities, which may remain after cutting. The edges of both paper faces may be trimmed up if
necessary, using fine sandpaper.
Bending
Gypsum board may also be used to line curved areas. The curvature radius will be 60cms for 9.5mm
Gypsum board. Both sides of the Gypsum board should be sprayed with water until they are damp.
The board should then be bent very slowly and carefully, and fixed into position. Before jointing, the
boards should be completely dry.
Process of Jointing & Finishing
1st application-- Embedding of paper tape into joints by using taping knife.
2nd application -- After first application is dried. Second finishing coat is applied
3rd application -- Final finishing coat application followed with topcoat.
Work procedure:
1. Ceiling
 Suspended Ceiling

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 Grid Ceiling
2. Jointing and Finishing
TOOLS USED FOR GYPSUM WORK
Taping Knife
100 mm wide taping knife, flexible steel bladed knife for embedding joint tape.
Applicator
200 mm wide rigid Bakelite blade with plastic grip for applying Geoboard jointing compound.
Electric Drill with Clutch Attachments
Converts standard electric drill to a power screwdriver suitable for fixing Gypboard to metal frame
system.
Crimping Tool
Punches and locks together 0.55 mm sections. Used for crimping at the base and head of the
partition or separating wall. Also used in Gypboard steel beam and column encasement system.
Anchor Fastener
It is of 12 mm diameter and 38mm long expandable aluminium alloy fastener. It is used to hold, the
suspended ceiling at 1220 mm in both directions. Each rawl plug can take load of up to 25 kg.
Connecting Clip
2.64 mm diameter spring steel wire made to suit and hold the ceiling section & intermediate channel
together to form a regular frame.
Screws
Drywall screws are self-drilling and self-tapping with counter sunk Philips head. These are
either oxidized or galvanized to avoid rusting.
Joint Paper Tape
A paper tape of reinforcing tapered edge joints and internal angles in both manual and mechanical
jointing systems. It has a centre crease, chamfered edges and slit perforation in four rows. Supplied in
120 mtr x 53 mm rolls, ten rolls to a pack.
INSPECTION METHODOLOGY FOR QUALITY ASSURANCE
1. Check for line level plumb using the same tools used for block masonry.
2. Ensure the joints are recessed to 4 mm to 5 mm at the joints to the width of the fiber mesh
3. Ensure fiber-mesh/ paper tape is fixed for all joints and horizontal corners
4. Ensure gypsum corner beads are fixed at all vertical joints
5. Gap between two boards should not exceed more than 5 mm.
6. Ensure joints of two Gypsum boards are treated with only jointing compound of Indian Gypsum
Limited and not Plaster of Paris POP.
7. Ensure horizontal bracings are provided for GI frame in partitions of more than 3m high.
8. Ensure horizontal bracings are provided for GI frame in slender partitions or places where switch

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plates, wall mounted fixtures, etc are fixed.

9. Avoid gypsum walls and partitions in water prone areas like toilets, pantry kitchen etc.
10. The dust from sanding at the joints should be removed either using soft cloth or soft broom
before start of painting works.
11. Ensure fisher plug with 35mm long GI screws are used for perimeter channel fixing and black
star screws of 25mm are used for fixing boards.
12. For prevention of cracks at joints ensure that:
 Paper tape is used and pressed properly at the joints
 'V' grove is cut & filled properly at square edge joint
 Drywall screws are properly driven with clutch attachment, arresting movement between
board & frame
 Vibrations of A.C. duct/ generators are not passing onto the ceiling/ partitions
1. Inspection Record:
2. Reference Documents:
3. Inspection Test Plan:

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METHOD STATEMENT
FOR
INTERNAL PAINTING WORK
INTERNAL PAINTING WORK

General
Paint is combination of resins, pigments, binders (natural or synthetic), additives and solvents.
Specifications: Plascon-Evans
There are various types of paints depending upon the material, base etc. Accordingly, the paint is
classified as mentioned below:
Material:

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 Filler materials for undulation, cracks, & smoothening

 Alkali resistant primer
 PVA acrylic emulsion paint
Base:
 Oil based paint
Basic Properties of paint:
 Durability
 Breathe ability
 Dust / dirt proof
 Washable
 Weather Proof
 Raw Materials, their Inspection and Acceptance
A) Paints:
1) Type of paint shall be appropriate as per Plascon-Evans specifications.
2) Other types of paint which are delivered in cans / drums shall be checked for following details on
The packing:
 Manufacturer’s name
 Batch and lot number
 Date of manufacturing
 Expiry date
 ISO / ISI mark
 Special instructions by manufacturers for proper mixing and application as also to maximize product
performance and minimize wastage.
 ECO mark (eco-friendly) (if any), stating criteria for which ECO mark is obtained.
 Percentage of toxic element like Lead, Cadmium and Chromium (if present)
4) Colour code as well as colour shade of paint shall be matched with that mentioned in the purchase
order before acceptance.
5) Paint cans after opening shall not give out foul odour.
6) Paint Manufacturer’s literature should clearly mention that following tests have been carried out in
the laboratory and shall mention satisfactory results for the same:
 Surface dry time
 Hard dry time
 Scratch Hardness
 Viscosity
 Opacity

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 Brush ability
 Flash point
 Volatile contents
 Concrete panel test
Crack Filling Material and Glue Adhesives:
Crack filing material as well as glue adhesives shall be of approved make and as recommended by
manufacturer / Architect and approved by QA Department.
Consistency Test / Penetration test:
After opening the can, a knife is introduced inside the paint and paint settings on knife are carefully
observed. No solid particles of paint should be observed. Also, while introduced knife no cake formation
should be observed in the can. After stirring the paint, a smooth uniform mix should be observed.
B) Other components (allied materials):
Primer:
Primer shall be of same make as that of paints / approved make as per the recommendations of the
paint manufacturer / Architect.
Thinner:
Thinner shall be of approved make and as per the recommendations of paint manufacturer / Architect.
Paint Brushes:
Brushes shall be of approved make with bristles in good condition.
Surface Finishing Rollers:
Surface Finishing Rollers shall be of approved make and be able to give necessary texture to finished
surface.
Other Materials:
Other materials such as glue, whiting powder, linseed oil, turpentine etc. shall be of good quality and of
approved make as per the recommendation of the paint manufacturer / Client / Architect.
Storage of Raw Materials:
Storing of Paints, Primers and Thinners:
1) Cans of Paint on receipt at site shall be sorted as per different manufacturers / as per their types.
2) Such sorted cans shall be stored on racks of height not more than 1.2 m and distance between racks
shall be kept as 0.8 m minimum. Cans shall be stored in such a way that Manufacturer’s name as well as
shade of the paint in the container is easily identifiable.
3) Primer and thinners shall also be sorted and stored near respective paint cans.

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Storing of Paint Brushes:

1) Paint brushes shall be sorted as per their size and stored in the same room as that used for storing
paints. Plastic packing over brushes shall not be removed till their use.
2) At random checks, bristles of brushes shall be checked for their proper anchorage.
Other Materials:
1) Other materials such as bags of readymade putty, glue, whiting powder, linseed oil, turpentine, POP
etc. shall be stored in the same room as that used for storing paints. Care being taken so that these
materials do not come in contact with water.
 Procedures for Internal Work:
Pre-Painting Procedures:
1) Experienced painters shall be employed to carry out all painting works.
2) Colour code and shade card from Manufacturer of paint in reasonable numbers shall be made
available on site.
3) The paint in the drum shall be thoroughly mixed prior to application. The materials shall be mixed,
prepared and applied strictly in accordance with the instructions or recommendations of the
manufacturers.
4) It shall be ensured that all kind of civil as well as Electrical works are completed prior to start of
painting works.
5) Main door shall be provided with locking arrangement.
6) Maximum 30 days gap shall be provided between starting of painting work and completion of
plastering work.
7) Moisture content in the wall shall be particularly attended to. When sufficient time is not available for
the surface of walls to dry out, walls shall be applied with lime wash, colour wash, cement paint or oil
free distemper which will allow drying process to continue at reasonable rate through their films. In any
case glossy paint shall not be applied till drying process is complete.
8) No painting work shall be carried out in wet and very humid weather when there is danger of dew or
weather is otherwise unfavourable.
Surface Preparation:
1) After ensuring that wall surface is totally dry, it shall be brushed with emery paper (sand paper) to
remove dirt, loose dust and efflorescence, if any.
2) If any cracks are observed on wall surface the same shall be cut into a V shaped groove with a round
wheel cutter to the depth equal to thickness of crack and the groove shall be filled with POP or Crack
seal. It shall then be allowed to dry completely.

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3) The entire plastered surface to be painted should be inspected for hollowness / voids, if any, and
necessary rectification should be done as per the guidance of QA Department.
During Painting Procedures:
1) Availability of all paints, primer, putty, thinner, glue, whiting powder, linseed oil, turpentine, brushes,
rollers etc shall be ensured prior to commencement of painting work.
2) The surfaces which are not to be painted shall be covered with empty cement bags or hessian cloth.
3) Paint to ceilings should be preferably done before paint to walls.
 Primer:
1) Only one coat of alkali resistant primer to applied (to be followed as per approved paint
Specification).
 PVA Acrylic emulsion paint:
1) Entire process of application is same as that for Oil.
2) Only two coats of paint are applied. (As per approved paint specification / As a general guideline, 500
ml of thinner shall be added to 1 lit of Oil Paint from can or as per manufacturer’s guidelines to be
followed with slight variation in quantity of thinner to obtain paint of desired consistency).
NOTES:
Thinners (such as mineral turpentine) shall not be added to paints on the feeling that the consistency of
the paint supplied by the manufacture is too thick. If the paint has been manufactured to conform to the
specification, the paint shall have the correct consistency and shall not require further dilution. If there
is any doubt, the viscosity of the paint may be checked. If a slight adjustment of viscosity is necessary,
thinner, recommended by the manufacturer shall be used after prior approval.
 PVA Acrylic Emulsion Paint:
1) Acrylic emulsion paint shall be prepared as per manufacturer’s instructions with slight alterations to
obtain paint of required consistency.
2) For an application of acrylic emulsion paint, absolutely smooth surface of plaster is recommended.
3) Donga application is not required over gypsum.
 Post Paint Procedures:
After application of final coat of paint satisfactorily, stains of paint shall be removed from doors and
door frames, tiling, skirting and hand railing, windows including glass panes, M S Grills, electrical switch
boxes etc.
Acceptance of Completed Work
Type of Check Acceptance

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Brush / Roller marks Shall not be observed

Dust / Colour patches Shall not be observed
Damp spots Shall not be observed
Texture Uniform
Shade variation Shall not be observed
Glue adhesion test Satisfactory
Coat thickness Satisfactory
Records :
ITP Reference No :
METHOD STATEMENT
FOR

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EXTERNAL PAINTING WORK
EXTERNAL PAINTING WORK

General
Paint is combination of resins, pigments, binders (natural or synthetic), additives and solvents.
Specifications
There are various types of paints depending upon the material, base etc. Accordingly, the paint is
classified as mentioned below:
Material:
 Cement paint
 Acrylic paint
 Textured paint
Base:
 Water based paint
 Oil based paint
 Polymer based paint

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Basic Properties of paint:

 Durability
 Breathability
 Dust / dirt proof
 Washable
 Anti-fungal / algae
 Water repulsive
 U V Resistance
 Raw Materials, their Inspection and Acceptance:

 Paints
1) Cement based paint / acrylic paint shall be appropriate make as per specifications of Architect.
2) Cement paints / acrylic paint which is delivered in HDP bags / drums shall be checked for following
details on the packings:
 Manufacturer’s name
 Batch and lot number
 Date of manufacturing
 Expiry date
 ISI mark
 Special instructions by manufacturer for proper mixing and application as also to maximize product
performance and minimize wastage.
 ECO (Eco friendly) mark (if any), stating criteria for which ECO mark is obtained.
 Percentage of toxic like Lead, Cadmium and Chromium (if present)
3) Colour code as well as colour shade shall be matched with that mentioned in the purchase order
before acceptance.
4) As a general guideline, this shall be done by mixing about 5 kg of cement paint with suitable amount
of water (Manufacturer’s literature shall be referred for this) to obtain paint of desired consistency and
then applying the paint in the form of vertical bands on already plastered exterior wall surface in 2 coats
with curing as specified later. Colour shade is then observed after 14 days, which should match with the
required shade, for the purpose of acceptance of paint.
5) Readymade acrylic paints are available in drum packing.
6) Paint Manufacturer’s literature should clearly mention that following tests have been carried out in
the laboratory and shall mention satisfactory results for the same:
 Surface dry time

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 Hard dry time

 Scratch Hardness
 Brush ability
 Concrete panel test
 Crack Filling Material and Glue Adhesives:
Crack filing material as well as glue adhesives shall be of approved make and as recommended by
manufacturer / Architect and approved by QA Department.
Paint Brushes:
Brushes shall be of reputed manufacturer with bristles in good condition.
 Procedures for External Painting Works (Cement & Acrylic):
Pre-Painting Procedures:
1) Experienced painters shall be employed to carry out all painting works.
2) Colour code and shade card from Manufacturer of paint in reasonable numbers shall be made
available on site.
3) It shall be ensured that all kinds of Civil as well as Electrical works are completed prior to start of
painting works.
4) Minimum 30-60 days gap shall be provided between starting of painting work and completion of
plastering work based on type of paint to be used.
5) Single / double scaffolding shall be erected as per required height.
Surface Preparation
1) After ensuring that wall surface is totally dry, it shall be brushed with emery paper (sand paper) to
remove dirt, loose dust and efflorescence, if any.
2). Wire brush to be used for cleaning the surface for any algae / fungal developments if any. Water jet
can also be used or both for the same.
3) If any cracks are observed on wall surface the same shall be filled with Crack filling material and
allowed to dry completely and cured, if required as per manufacturer’s specifications.
4) Edges shall be particularly attended to and finished to line and level.
5) The entire plastered surface to be painted should be inspected for hollowness / voids, if any, and
necessary rectification should be done as per the guidance of QA Department.
During Painting Procedure:
1) Availability of all paints, glue and crack filling material shall be ensured prior to commencement of
painting work.

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2) The surface shall be wetted at least 2 Hrs prior to painting for cement paint. For acrylic paint, wetting
of the surface is not necessary. However, manufacturer’s recommendations should be followed for the
same.
3) Paint shall be prepared as per manufacturer’s instructions.
4) When weather condition is very dry, the work shall be carried out ‘in the shadow’ by providing
curtains.
5) Paint in the buckets shall be continuously stirred to obtain uniform mixture and to prevent
segregation.
6) Waterproof polymer coat for dead walls is necessary to avoid leakages. However, application of
primer coat is also necessary before polymer coat or as specified by manufacturer.
7) Anti-fungal / repellent coat for all walls except dead walls is necessary to avoid development of
algae / fungus on painted surface. This coat can be done with the help of spray machine.
8) 1st coat of paint shall then be applied. Application with brush shall be one stroke downwards, one
stroke upwards and one stroke from left to right.
8) After cement paint has hardened (i.e., 12 hrs. after application of cement paint) it shall be cured.
Curing shall be carried out by fogging (using a fog spray)/ sprinkling by water 2-3 times a day for 2 days.
9) For acrylic paint curing is not required. Here a gap of minimum 8 hour should be maintained between
two coats.
9) In hot, dry weather, 1st coat shall be moistened before application of 2nd coat. (For cement paint
only)
10) 2nd coat of paint is then applied just like 1st coat and cured in the same manner. Curing of 2nd coat
shall be carried out for at least 2 days. (Curing should be done for cement paint only whereas no curing
is required for acrylic as well as textured paint)
11) Painted surface can be protected from hot sun and wind by providing wet Hessian cloth barriers.
12) 3rd coat shall be applied, if specified in work order / by Architect. 3rd coat thickness shall be thinner
than the first two coats.
13) However entire painting work can be done by spray machine.
Post Painting Procedures:
After application of final coat of paint satisfactorily, stains of paint shall be removed from doors and
door frames, tiling, skirting and hand railing, windows including glass panes, M S Grills, electrical switch
boxes etc.
Synthetic Resin Base Coat with Acrylic Overcoats (renova) in Plain / Stone / Metallic finish
(Procedures):

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1) The surface shall be thoroughly cleaned off all dirt, dust, mortar dropping and other foreign matter,
before paint is to be applied.
2) Application of primer coat is necessary over the entire surface to be texture painted.
3) Synthetic plaster reinforced by using fibre and based on a chemical which is superior type of cladding
material having acid and alkali resistant properties, can be applied to any hard based plain surface both
internally and externally. It does not require any further application or treatment once it is applied on
the surface. It is available ready-mixed for any desired colours which can be applied by a trowel. This will
avoid cracks formation as well as provide a waterproofing coating on the surface treated.
4) A cement plaster base is required which shall be roughened lightly with wire brush so as to form very
mild keys. The surface shall be well cured before the application of synthetic plaster.
5) Synthetic plaster then be applied in five coat i.e. one coat of plaster by trowel and subsequent four
coats of chemical overcoat by brush in approved colour and finish as specified (plain / stone or metallic).
Brush / Roller marks Shall not be observed
Dust / Colour patches Shall not be observed
Damp spots Shall not be observed
Texture Uniform
Shade variation Shall not be observed
Glue adhesion test Satisfactory
Coat thickness Satisfactory
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TILING, SKIRTING, TOILET DADO &
PLATFORM WORK

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TILING, SKIRTING, TOILET DADO & PLATFORM WORK
Raw Materials
Cement:
1) Cement shall be OPC 42.5NGrade or PPC and not more than 8 weeks old
Natural Sand:
For tiling works no detailed checking of sand is required. Sand for wall tiling should be 600 microns
passing.
Water:
Water for Tiling Works following checks are important on water used for curing to avoid efflorescence:
 Sulphates: Not greater than 0.05 %
 Chlorides: Not greater than 0.10 %
Admixture: Admixture like tile adhesives / liquid tile adhesives (can be used for better bonding) shall be
from reputed manufacturers. Care shall be taken to see that it is compatible with the Type / Brand of
cement being used.
Grouts, Adhesives, Colouring pigments, Spacers, Masking tape:

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1) Grout used for sealing of gaps between tiles shall be of approved make and shall be stain resistant.
Adhesives shall be of approved make.
2) If specified, Colouring pigments matching with the shade of tiles shall be used.
3) Spacers and masking tape shall be as suggested by Architect.
Mortars for tile bedding:
Approved mix from Client / QA Department shall be used for mortar for tile bedding as well as wall tiles
Tiles:
Tiles shall be vitrified, Ceramic, Glazed or Porcelain of make and colour as specified on drawings in the
specification. Tiles, on receipt of every lot, shall be checked visually for any cracks, chipped surfaces,
colour variation and arrow mark. If tiles are not found satisfactory, then the entire lot of tiles shall be
rejected. However, following tests shall be carried out on tiles for every receipt of lot, for their
acceptance.
Testing frequency of tiles shall be after every 2000 tiles (considered as a lot) from the same
manufacturer for same colour / size / type or when the source of supply changes.
For testing purpose number of tiles selected shall be as per table. Tiles shall be selected at random and
subjected to following tests and acceptance criteria.
 Failure of 2 or more tiles as per tolerance given in Table shall be liable for rejection of entire lot.
 If only 1 tile fails to satisfy criteria, then retesting of tiles shall be carried out as earlier on fresh tiles.
No tile should fail in retesting considering tolerances.
Tests on tiles:
Dimensional Analysis for tiles:
A) Measurement of length and width:
 10 tiles shall be chosen at random from a given lot.
 Length and widths of all tiles shall be measured between end corners of tiles. (Leaving 5mm from
corners)
 In all 40 readings shall be obtained.
 Average of these 40 readings shall be compared with the ordered sizes of tiles.
B) Measurement of thickness:
 Diagonals shall be drawn on all tiles. Thickness of tiles shall be measured at the centre of 4 segments
so formed with the help of micrometre.
 Average thickness of all 40 readings shall be calculated and shall be compared with the specified
thickness of tile.

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C) Measurement of straightness of sides:

 For measurement of straightness of sides, a steel square shall be used. Deviation from straightness _
(delta) shall be measured as the difference of straightness between that at 5mm from corners of
tiles and that at centre of corresponding edge of tile.
D) Measurement of rectangularity
 Tiles shall then be placed over a steel plate with studs at 5mm from corners.
 Difference in size, _ of tile is checked at 5mm from corners for all four sides separately, by rotating
the tile.
 Deviation of rectangularity for each side shall be: Δ *100 / L, where L is corresponding length of tile.
Field test:
About 2” high bed of sand shall be made on site and levelled. Tiles chosen for test shall be placed on
them touching each other so as to form sufficiently levelled top of tiles. Number of tiles to be chosen for
testing shall depend upon the size of tiles, for which following table is given.
SIZE OF TILES NO. OF TILES CHOSEN FOR TEST

350 mm x 350 mm 20
152 mm x 152 mm x 5 mm 20
After placing the tiles on sand bed, diagonal length of the square so formed shall be measured and
diagonal length shall be match with the calculated diagonal length. No tolerance shall be allowed on
diagonal length measured.
E) Surface Flatness:
 A flat calibrated plate of steel or glass 10mm thick with studs is used for determining a plane by
adjusting studs at three corners of tile (5mm away from corner)
1) Center of curvature:
∂ (Center of curvature) is the difference in level at the centre of tile and the level of plane as determined
above
2) Edge of curvature:
∂ (Edge of curvature) is the difference in level at the centre of edge of tile and the level of plane as
determined above.

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3) Warpage of curvature:
∂ (Warpage) is the difference in level at the fourth corner of tile and the level of plane as determined
above.
F) Water Absorption Test for Ceramic / Glazed tiles:
 5 tiles are chosen at random from a given lot (Area of each tile >400sq.cm), whereas 10 tiles shall be
chosen (Area of each tile <400 sq.cm).
 Tiles having sides larger than 200 mm, shall be cut into pieces (Each having area <400 sq.cm), but all
tiles’ pieces, so formed shall be tested.
 Tiles to be tested shall be oven dried and then cooled to room temperature and weight of each tile
m1 is noted.
 Tiles are then kept immersed in distilled water, each tile separated from each other and kept
immersed in water in such a way so as to keep 50 mm water depth above and below the tiles.
 Water in then heated till boiling temperature and tiles are kept immersed in boiling water for about
2 Hrs.
 Tiles are then wiped dry with Chamois leather and placed in cold water for about 4 Hrs. and wt of
each tile m2 is noted.
 Percentage of water absorption = (m2-m1) *100/m1 and shall not be greater than 10%.
NOTES:
Vitrified tiles are not soaked before fixing.
G) Scratch test:
 At least 3 tiles are chosen randomly from a given lot.
 With the help of sharp nail 4 lines are drawn on each tile, by applying uniform pressure. No scratch
mark should be observed.
Reference shall be made to Table 1 for acceptance criteria of tiles.
TABLE 1: Guidelines for Inspection of Tiles

Sr. Description Mode of Inspection Acceptance Frequency
No. Criteria
1 Dimensional Field test: Every 2000 tiles
Analysis (10 tiles Length-Ceramic, Porcelain and glazed tiles. ±1 mm or source changes
from lot)
Width- Ceramic, Porcelain and glazed tiles ±1 mm
Thickness- Ceramic, Porcelain and glazed tiles ±0.5 mm
Length-Vitrified Tiles ±0.5 mm

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Width- Vitrified Tiles ±0.5 mm

Thickness- Vitrified Tiles ±0.5 mm
2 Measurement of Field test No Every 2000 tiles
straightness (10 tiles deviation or source change
from lot)
3 Measurement of Field test No Every 2000 tiles
Rectangularity (10 deviation or source change
tiles from lot)
4 Surface flatness (10 External Lab test ±0.2 mm Every 2000 tiles
tiles from lot) or source change
5 Canter of curvature External Lab test ±0.2 mm Every 2000 tiles
(10 tiles from lot) or source change
6 Edge curvature (10 External Lab test ±0.2 mm Every 2000 tiles
tiles from lot) or source change
7 Warpage (10 tiles External Lab test ±0.2 mm Every 2000 tiles
from lot) or source change
8 Water absorption External Lab test <- 10% Every 2000 tiles
2
5 tiles(area>400cm ) or source change
10
tiles(area<400cm2)
9 Scratch test (At least Field test No scratch Every 2000 tiles
3 tiles from lot) mark or source change
observed
on tiles.
NOTES: Above tolerances are recommended for achieving good workmanship at site. (IS/EN standards
being quite liberal)
Procedure for flooring and skirting works:
 Flooring
A) Pre-Tiling Procedures (Flooring):
1) Latest architectural drawing shall be made available on-site indicating start point, joints, level, offset,
type, colour, size and laying pattern etc.

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2) Conduiting works, if required, on a slab surface shall be completed. Nahani traps as well as washing
machine outlet pipe shall be provided as shown on the drawing.
3) Slab surface shall be cleaned by chipping if required, and wetted thoroughly. The naked slab shall be
treated with cement slurry with non-shrink material to avoid seepage of water below through shrinkage
cracks, if any.
4) Tile layout shall then be marked on the floor, with correct size of tiles, and clear-cut marking of
starting point for fixing of tiles shall be done. Tile edges being kept at right angles to plastered faces of
walls or as specified in drawing.
5) It shall be ensured that quality of tiles is satisfactory as per approved sample and proper sorting of
tiles should be done to have uniformity in size, colour and shade room wise.
6) Proper thiyya (level pads) s of tiles shall be taken at all four corners of rooms where tiles are to be
fixed and shown to the site in charge / site engineer before work begins. Floor level offset (1/2”
minimum or as specified on drawing) and slope shall be considered while taking thiyya (level pads) s for
toilets and terraces.
7) Floor thiyya (level pads) s shall be taken starting from stair landing and passage area first and then
within the rooms, keeping proper offsets (if any) as mentioned on drawing. Thiyya (level pads) s thus
taken for entire floor shall be checked by site engineer before tiling is started in any of the rooms.
8) Finished floor level so decided shall be clearly marked on each wall.
B) During Tiling Procedures (Flooring):
1) Tiles (Ceramic and Glazed) shall be soaked by completely immersing tiles in water for about 3 hours
and then drained for minimum period of 30minutes prior to their fixing in position.
2) Recommended mix proportion for mortar bedding should be used as per manufacturer’s specification
and/or approved by Q A Department.
3) If mortar bed thickness works out to be more than 2”, then the additional thickness shall be made of
by placing nominal screed concrete (PCC (1:3:6) mix or as specified by Client / QA Department) and it
shall be cured for at least 3 days and then fresh mortar shall be laid over it.
4) For laying of tiles alternatives below shall be followed:
Alternate 1:
 Once mortar bed dries sufficiently cement slurry shall be laid (cement or Cement+ LTA (liquid tile
adhesive) as per manufacturer’s specification) over mortar bed and levelled using straight edge.
 Tiles shall be laid simultaneously as cement slurry or Cement + LTA is spread along with Bonding
agent (if specified) and laying shall be done so that all joints of tiles match without showing any
offsets.

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Alternate 2:
 Mortar bed is cured for 3 to 7 days. Rich cement sand mortar (1:1) 4-5 mm thickness; using fine sand
shall be applied over cured mortar bed.
 Tiles shall be laid simultaneously as rich cement sand mortar is applied and laying shall be done so
that all joints of tiles match without showing any offsets.
For tiles of size 900 x 900 and above; alternate 2 shall be adopted.
5) Use of arrow marks at the back of tile shall be made while fixing tiles. Straightness of joints shall be
maintained throughout. Tile fixing procedure shall be confirmed from the manufacturer, if required, or
under special circumstances. This is especially required when a particular design pattern is required on
the finished tile surface.
6) Each tile after placing shall be tamped with rubber mallet to form accurately levelled surface.
Hollowness beneath the tiles shall be checked from time to time by tamping and checking the sound
produced. Corners of tiles shall be specially attended to for checking hollowness beneath.
7) It is strongly recommended that all tile joints shall be maintained with the help of spacers (gap 1.5mm
and above) and filled with approved sealant of matching / contrast colour. However, architectural
drawings shall be followed.
8) Polyurethane foam of 5-6 mm thickness shall be provided along all four edges of room to cater for
expansion of tiles where spacers are not provided.
9) Proper offsets as well as slope (1:100 recommended or as specified on drawing) shall be provided for
tiles in toilets as well as tiles in attached terraces. Offsets shall be provided using 40x40x3 aluminium
angles. As far as possible, threshold patti should be used.
10) Skirting tiles shall be fixed over floor tiles.
11) Antiskid tiles are recommended for stairs, toilets and attached terrace and joint free rectified tiles
are recommended in kitchen area for hygiene consideration. It is recommended that floor tiles of
swimming pool be fixed using LTA.
C) Post Tiling Procedures (Flooring)
1) Next day joints of tiles shall be raked little with thin metal sheet and filled with grout of matching
shade and cured for at least 3 days. Use of half round tool shall be made for filling joints, where spacers
are used.
2) After curing is over, joints of tiles shall be covered with masking tape to prevent entry of dirt into it
and shall be covered with a layer of POP with paper underneath, for protection against scratches due to
dragging of objects over them as also stains caused due to dropping of acids, detergents and other
heavy objects and footmarks.

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3) Natural stone tiles shall be polished after a gap 15 days after fixing of tiles and polished surfaces shall
be well protected as above.
4) Staircase treads shall be checked for perfect line dori from topmost tread to bottommost tread.
 Skirting:
1) Skirting work shall start after masking of joints in tiles is complete.
2) It is recommended that skirting face shall be flush with wall plaster face and groove above skirting
shall be avoided since dirt accumulates within the groove. However, architectural drawings shall be
followed.
3) Where Architect has particularly recommended skirting to fixed in offset with plaster, following
precaution shall be taken:
a) Wall plaster shall be completed in perfect plumb and line leaving a gap of height (50-100mm more
than skirting height, at bottom).
b) Temporary thiyya (level pads), using skirting tiles shall be taken from wall by fixing two skirting pieces,
one at each end of the wall and line dori shall be stretched across them.
c) Skirting tiles shall be fixed in plumb with the thiyya (level pads) so taken.
d) Gap above skirting shall be applied with plaster and trowelled flush with plaster above.
e) This is to ensure uniform offset of skirting over plaster.
4) Skirting edges and floor tile edges shall perfectly match.
5) Skirting at offsets shall be matched at 45º to show a clean edge.
6) Skirting shall be fixed in such a way so as to keep its top level in perfect line and level of plaster.
Staircase
1) Tiles over staircase shall be anti-skid type unless specified otherwise by Architect.
2) If natural stones/natural stone tiles are used over steps, at least three grooves shall be made near
nosing.
Procedures for Wall Tiling
a) Pre-Tiling Procedures (Wall tiling/Dado)
1) Latest Architectural Drawing shall be made available on site.
2) Finished plaster surface shall be checked for right angles and diagonal shall be corrected for the same,
if not found satisfactory.
3) It shall be ensured that chases in masonry made for concealed piping are properly rendered with
application of chicken mesh, non-shrink mortar and cured. It must be ensured that electrical boxes are

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fixed in position. All rendering works as well as minor repair works using mortar shall be cured using
curing compounds or as directed by Quality Department.
4) Wall tile thiyya (level pads) s shall be taken before fixing of plumbing pipe outlets and wall tiling
layout shall be clearly marked on the plastered surface with clear cut marking of starting point.
5) Nominal mix proportions for mortar tile fixing shall be decided by Quality Department.
6) Tiles (Ceramic and Glazed) shall be soaked by completely immersing tiles in water for about 3 Hrs. and
then drained for a minimum period of 30 minutes prior to their fixing.
7) If tiles are to be fixed up to ceiling thiyya (level pads), ceiling thiyya (level pads) shall be checked for
perfect horizontal thiyya (level pads) and necessary rectification shall be carried out to achieve the
same, if required.
8) The wall on which maximum plumbing work is done shall be chosen first for fixing of wall tiles.
9) Plastered wall surface shall be wetted thoroughly 12 hours prior to time chosen for fixing wall tiles.
b) During Tiling Procedures (Wall tiling / Dado)
1) It shall be ensured that quality of tiles checked from QA Department. Also, proper sorting of tiles shall
be done to have uniformity in colour and shade. Starting point for each wall shall be followed strictly as
per drawing.
2) Ensure mix proportions from QA Department to form mortar of suitable consistency.
3) Use of Liquid Tile Adhesive is recommended while making mortar.
4) Mortar, thus prepared, shall be used before initial setting time of cement or cement fly ash mix.
5) Use of neat cement paste for fixing tiles shall be avoided.
6) Circular holes of required size shall be made on tiles at appropriate positions as determined from
markings on wall. Holes shall be made from back of tiles with the help of cutter machine.
7) Mortar shall be applied to back of each tile (8-10 mm thk coat of mortar) before fixing in position and
then tamped with rubber mallet to remove hollowness behind. Thickness of compacted mortar bed shall
not exceed 8mm.
8) For dado works in toilets, walls shall be marked with tile fixing layout with correct sizes of tiles to be
fixed. Tiles shall be fixed from bottom second layer (full tile) to top leaving bottom most layer of tile.
Each tile shall be fixed in plumb with tile thiyya (level pads) piece using plumb bob. Also, line dori shall
be stretched between two corner tile thiyya (level pads) pieces and all tiles shall be fixed in plumb with
line dori. Bottom most layer shall be laid after fixing floor tiles. Bottom most tiles shall be cut to correct
slope of floor laid, before fixing. Care shall be taken so that top edge of bottom most tiles thus fixed is
perfectly horizontal. It should be ensured that bottom support should be removed 2 hrs. after
completion of wall tiling work.

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9) Fixing of wall tiles in other areas including passage (where no slope is given to floor) shall be done
after floor tiles are laid and sequence shall be from bottom to top.
10) Cement slurry shall be poured within the gap between tiles and plaster after every two courses of
tile laying. This is to ensure that there are no voids left behind the tiles fixed.
11) Cleaning of the tile surface should be done immediately after completion of laying of tiles.
12) For other precautions to be taken, refer section of floor tiles. For kitchen flooring, slope should be
provided towards Nahani trap and waterproofing should be completed to sunk portion of nahani trap
and after completion of curing period flooring should be laid. The other procedure of kitchen flooring is
same as regular flooring.
c) Post Tiling Procedures (Wall Tiling / Dado)
1) Next day joints of tiles shall be raked little with thin metal sheet and filled with grout of matching
shade and cured for at least 3 days.
2) It is recommended to keep one floor tile box (as spare) for each flat for initial maintenance / repair
before possession and for subsequent handing over of remaining tiles to occupant.
 Finished Product Acceptance
OPENINGS FOR DOORS / WINDOWS
Frame fixing In perfect line, level and plumb
Exposed edges of frames Properly rounded / chamfered
Rebates/holes in frames As specified on drawings
Joints in frame members Shall not be allowed unless length is excessive
Colour shade of gap filling As specified
Floor Tiling and Skirting
Bends in tile surface Not accepted
Defects in uniformity of joints Not accepted
Level difference in joints Not accepted
Defects in straight line of joints Not accepted
Variation in tile sizes at wall ends Not accepted
Variation in right angle of skirting with floor tiles Not accepted
Variation in right angle at corners of skirting Not accepted
Variation in top level of skirting Not accepted

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Defects in grooves at top of skirting Not accepted

Difference in floor level of individual room Not accepted
Floor tile joints not matching with skirting joints Not accepted
Offsets provided in floor levels of toilets and terraces As specified on drawing
Joint filling of floor tiles as well as skirting Satisfactory
Tiles sounding hollow Not accepted
Butt filling for skirting Satisfactory
WALL TILING FOR KITCHEN AND TOILET
Bends in tile surface Not accepted
Variation in Joint Thickness Not accepted
Variation in plumb of finished wall tile surface Not accepted
Level difference at joints Not accepted
Additional checks for Toilet dado
Undulations in the top level of tiles for dado in toilet Not accepted
Defects in straight line of joints Not accepted
Finishing of cut-outs Satisfactory
Variation in right angle of walls Not accepted
Quality of joint filling Satisfactory
Inspection Record :
ITP Reference No :

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ALUMINIUM DOORS & FRAMES AND
WINDOW FRAMES

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METHOD STATEMENT FOR ALUMINIUM DOORS & FRAMES AND WINDOWFRAMES
1.0 SCOPE OF WORK

The work covered by this specification consists of supplying and installing
Aluminium Doors, Windows, ventilators etc. (sliding or hinged type) or as per approved drawing.
In case of conflict between the clauses of this specification and those in the standard, this specification
shall govern. In case of conflict between design basis or job specification and those in these
specifications the former shall govern.
2.0 GENERAL
The basic design of aluminium Doors, Windows and Ventilators shall conform generally to SANS
(Specification for Aluminium Doors, Windows and Ventilators) & SANS (Specification for Aluminium
Windows for Industrial Buildings). The Aluminium alloy used in the manufacture of extruded sections of
approved make shall correspond to SANS and the hollow aluminium alloy sections shall correspond to
SANS. The aluminium alloy coupling sections used shall conform to SANS.
Aluminium sections shall be powder coated or anodized as per specified in drawings.
The dimensions, minimum thickness and wt. per meter run of the extruded sections shall correspond to
the related drawings and specifications given for the work.
The approximate size of the windows and ventilators are given in the drawings for guidance. Slight
modifications in the dimensions are permissible to suit the sizes of manufacturers.
Minimum wt. of extruded Aluminium sections are as under or as specified in the drawing
A) Doors For fixed frame:- a) Side& top member 1.975 kg/m b) Lock rail 1.594 kg/m c) Bottom rail
3.495 kg/m Glazing clips (beading) 0.182 kg/m For shutter frame 1.202 kg/m
B) Window /Ventilator: a) For fixed frames 0.639 kg/m b) For shutter frame 0.636 kg/m c) Glazing
clips (beading) 0.165 kg/m d) Coupling bars 0.933 kg/m e) Member for fixing the frame 0.463 kg/m.
2.1 Raw Materials, Their Inspection and Acceptance Criteria
Aluminium Sections:
1) Aluminium section shall be of reputed make / manufacturer as specified. Technical brochure /
literature for the same shall be made available on site from manufacturer.
2) Size, thickness and weight of Aluminium sections shall be as specified and approved in the sample. It
shall be checked on site after delivery and properly recorded. Weights of sections shall fall within the
range of ±10%.

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3) Anodizing / powder coating/ shall be carried out through reputed applicators and shall have approved
shade and satisfactory finish. The coating shall be uniform and without scratches.
4) Anodizing thickness shall be restricted to 15 to 20 microns whereas powder coating thickness shall be
restricted to 65 to 80 microns.
5) All sections, including that of frames shall be perfectly straight, without any bends, twists etc.
6) Aluminium section shall preferably be cut and drilled prior to anodizing / powder coating to avoid
causing burrs or disturbance to the coating during their cutting to required sizes.
7) Burrs, if any, shall be de-burred using de-burring tool. Proper record of cut section with coding system
shall be maintained on site for assembly later.
8) Protective masking tape shall be applied over Anodized / Powder coated aluminium sections to the
full depth.
9) Approved samples of coated aluminium sections shall be made available on site for comparing with
new incoming material for cross checking.
2.0 SHOP DRAWINGS

The contractor if so directed shall submit four sets of shop drawings covering items of
work of this specification. The drawing shall show all dimensions, details of construction and
installation relating to adjoining and related works where same requires cutting or close fitting and
shall show all the reinforcement, gauges of metal, nomenclature of the various standard sections
used, welding anchorages or holdfasts, positions of all fittings and fixtures. Various units shall be
properly marked and their correct position shall be indicated. The marks and directions so indicated
shall be painted on the fabricated members to facilitate erection at site. The work of fabrication
shall be taken up only after the shop drawings are approved by the Owner.
3.0 FABRICATION
Frames shall be square and flat; the corners of the frame being fabricated to a true right angle. Both
the fixed and opening frames shall be constructed of sections which have been cut to length, mitred
and welded at the corners. Where hollow sections are used with welded joints, argon arc welding or
flash butt welding shall be employed. Subdividing bars of units shall be tenoned and riveted into the
frame.
For hinged doors, windows, ventilators etc., proper reinforcement shall be provided for the hinges
so as to prevent the sagging of the doors, windows etc. at a later stage. The material and design of
the hinges shall be got approved by the owner/consultant before use.

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The frames for doors, windows, ventilators etc. shall show no wrap or inferior workmanship. The
frames shall be designed for glazing on the outside of the frames unless specified otherwise.
Ventilators consisting of an inner opening frame and an outer fixed frame, shall be made as separate
units.
The Doors, Windows, Ventilators etc. shall be provided with necessary glazing bars as per drawing.
Weather bars shall be fitted to coupling sections wherever required.
Holes for fixing and coupling sashes shall be provided in the web of outside frame sections and of
outer ventilator frame sections where these occur at the perimeter of the sash.
Holes for glazing clips shall also be provided, one hole being located in the web of the section or tee,
on each side of the pane.
4.0 DOORS
For Doors, the outer frame \and sections shall be of aluminium extruded sections conforming to
SANS. The door shall be provided with glazing / infill panel which shall be fixed by means of
triangular clips and gaskets of suitable material as approved by the owner / consultant. All fixtures
and fastenings including hinges, tower bolts, decorative type handles, safety locking arrangement
etc. of approved make shall be provided.
The doors shall be provided with floor spring boxes if specifically required by the owner / consultant.
Door panel shall be 12 mm thick prelaminated particle board phenol bonded as per drawing.
6.0 WINDOWS
The windows shall be made from extruded aluminium sections of approved make conforming to
SANS.
6.1 SLIDING WINDOWS
The outer frame shall be suitable for 2 track / 3 track / 4 tracks sliding as per requirement with
standard sliding shutter frame with top, bottom and vertical interlock system as per specification
and drawing.
Each shutter shall be provided with 2 nos. specially designed nylon moulded guides at bottom and
top with weather strip of suitable material all round on each sliding shutter and other accessories
for preventing leakages.

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Special approved locking arrangement and two sets of nylon roller with bearing of approved quality,
handles and other fixtures shall be provided in each shutter.
Each shutter shall be provided with sheet glass / other specified material with approved quality
packing material around glass, glazing clips etc. as per specification.
Necessary approved hardware fittings shall be provided and fitted.
6.2 OPENABLE WINDOWS
The outer frame shall be made up of ‘Z ‘sections with intermediate transom or mullion sections as
per specification.
Each shutter shall be provided with all necessary fixtures and fastenings including aluminium
fastener type handle, aluminium stays, hinges, locking arrangement etc. as per specification.
6.3 FIXED TYPE WINDOWS
For fixed type windows, the outer frame shall be of aluminium single side groove sections with
intermediate double side groove sections at specified intervals as per specification.
6.4 LOUVRED TYPE WINDOWS
For louvered type windows, the outer frame shall be of aluminium single side horizontal groove
sections with intermediate vertical members of horizontal double side groove sections at specified
intervals as per specification.
The louvers shall be of glass / other specified material and shall be fixed on with heavy type
aluminium channels of @ 10mm x 10mm of approved size having one end closed to rest louvered
glasses at required intervals.
7.0 VENTILATORS
The ventilators shall be made from extruded aluminium sections conforming to BSI
7.1 TOP / BOTTOM HUNG VENTILATORS
Both Top hung / Bottom hung ventilators shall be hung on aluminium alloy hinges which shall be
either cast or fabricated out of extruded sections. The aluminium alloy for cast hinges shall conform
to A-5-M of SANS and for extruded section of hinge to SANS. Top hung ventilators shall be provided
with a 300mm long peg stay of cast aluminium to A-5-M of SANS or folded from NS4 Aluminium
sheet of SANS complete with cast aluminium peg and locking bracket. The stay shall be welded or

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riveted on to the bottom inner ventilator frame section and shall lock into the locking bracket of
similar material welded to the bottom outer ventilator section.
Alternately top hung ventilators may be provided with a 30cm cam opener of aluminium alloy to A-
5M of SANS fixed to the ventilator. Both peg stay and cam opener shall be capable of holding the
ventilator open in three different positions.
Bottom hung ventilators shall be provided with a pair of aluminium alloy folding side arms to limit
the opening of the ventilator. The aluminium alloy arms shall be either cast in alloy A-5-M of SANS
or fabricated from aluminium alloy sheet conforming to NS4 of SANS. When ventilator is closed, the
side arms shall be invisible.
7.2 CENTRE HUNG VENTILATORS
Centre hung ventilators shall be mounted on a pair of cup pivots made out of aluminium alloy sheet
conforming to NS 4 of SANS and A-5-M of SANS or of material approved by owner / consultant. The
ventilator shall be so balanced that it shall be capable of remaining open in any desired position
under normal conditions. Spring catch, catch -plate, cord-eye etc shall also be provided for proper
functioning of the ventilator.
8.0 GLAZING
All glass used for the purpose of glazing shall be float glass, clear, ground, figured or wired sheet
glass of the best quality as directed, thickness of glass shall be 4 mm thick for windows and 5.5 mm
thick for doors and partition wall with corresponding weights as recommended in relevant IS
specifications. All glass shall be free from blisters and all other defects and shall be fixed to the
frames by means of glazing clips, and approved putty. The number of glazing clips shall be 4
minimum per panel. The glazing may be fixed also by means of aluminium extruded beading
screwed with countersunk screws to the frames if approved by the owner / consultant. The glazing
shall conform to SANS.
No glazing shall be considered complete until all stains have been removed from the surface of the
glass. If directed, the glass shall be cleaned with spirit or any other approved material to remove
stains.
9.0 HANDLING OF DOORS, WINDOWS AND VENTILATORS
Care shall be taken in unloading and stacking windows and ventilators at site. They shall be
examined for any damage that may have occurred in transit and shall then be stacked upright (on

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their sills) on level ground, preferably on wooden battens and shall not come into direct contact
with dirt or ashes.
Care shall be taken in ensuring that aluminium frames are not allowed to get into direct contact
with wet cement and mortar. During the period of storage, aluminium should be protected from
loose cement and mortar by means of suitable covering such as tarpaulins.
The tarpaulin shall be hung loosely on temporary framing to permit circulation of air to prevent
condensation.
10.0 INSTALLATION
Frames shall be installed and fixed in masonry / concrete structures as shown in the drawings to
plumb and true line that operation is easy and smooth. Parts such as hinges shall be cleaned off the
construction waste and shall be cleaned and polished with petrol/ and other agents as specified by
the manufacturer. The main frame of Doors, Windows, Ventilators shall be fixed in masonry or
concrete sections with approved quality and size screws at about 300mm c/c after drilling the holes
using raw plugs as approved by owner/ consultant.
If any other fixing method is adopted, it shall be got approved by the owner / consultant before
commencement of work.
11.0 ANODIZING
All aluminium sections shall be anodized in natural matt finish with an anodic film thickness of 40
microns or as specified in drawing. The anodizing must be seated by keeping the anodized sections
in boiling de-ionised water for a period of one hour. The aluminium frame shall be cleaned and
polished with petrol or any other agents as specified by the manufacturer.
A thick layer of clear transparent lacquer based on methacrylates or cellulose butyrate, shall be
applied on aluminium doors, windows and ventilators by the suppliers to protect the surface from
wet cement during installation. This lacquer coating shall be removed after installation is completed.
12.0 POWDER COATED:
All aluminium section shall be powder coated of minimum 30 microns or as specified in
drawing or as per owner/ consultant.
Acceptance of Completed work
Type of Defect Acceptance
FRAME
Plumb and right angle In plumb

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Fixing of screws By drilling holes and staggered, spacing as

specified
Holes Satisfactory draining
Damage of frame after fixing Not accepted
Gaps between frame and plaster as also between Filled with silicon sealant of matching colour
different members
Window frame bottom Cleaned with air blower
DOORS
Door when slides Smooth operation and no rattling noise
Number of roller bearings As specified (minimum two per shutter)
Damage to Doors Not accepted
Easy removal of doors from frame Not accepted
Shutters locking With minimum effort and no noise
Rubber gasket / wool pile / EPDM gasket Good quality and fixed at proper position
All doors As per drawing
When all shutters are fully closed and checked No leakage of air should be observed
with vacuum cleaner
Gaps between window frame and plaster Filled with approved silicon sealant of matching
colour / transparent colour
Shutters obstructing while opening Not acceptable
Cleaning of shutters done With air blower
Records :
ITP Reference No :

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ROOFING SHEETING

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ROOFING SHEETING / CLADDING

1. PURPOSE:
The purpose of this document is to state the requirements of material, workmanship and construction
procedure to be followed during the execution of metal sheet roofing and cladding works.
2. SCOPE OF WORK
The work described herein shall cover providing and installing metal sheet roofing and cladding
including translucent sheets and all accessories such as flashings, capping, gutters, trims, supporting
straps, brackets, foam fillers, sealants and the work shall be carried out in strict accordance with this
specification and applicable drawings. Contractor should along with the supplier of the product shall
prepare shop drawings for roofing, cladding, gutters etc. and shall take the approval ofConsultants prior
to manufacturing and supply. Based on roof slope, the climatic conditions at site considering the
refinery atmosphere site nearing coastal area and the span of roof and slope of the truss / portal , The
sheet supplier / Contractor shall propose the type of profiled sheet , Base metal thickness of the sheet ;
yield strength of the sheet ; the Galvalume coating thickness and the pre-coated paint type & it’s primer
and final coats thickness, colour and retention parameters in case of Pre-coated Galvalume / Aluminium
sheets to be used and the proposal shall be justified through proper calculations.
3. TECHNICAL REQUIREMENTS
On site roll forming shall be done if the Owner/consultant requires single length of roof sheet from
ridge to the eaves for leak-proof roof. Leak-proof roof system with 10 years performance warranty shall
be provided.
MATERIAL
3.1.1 General
Material for sheets and accessories shall strictly conform to SANS/BIS/BS/ASTM/AS
Specifications as mentioned. Supplier shall furnish test certificates for verification of the
Same and shall make arrangements for inspection and marking of the materials at his works.
Erection shall not be started before approval of materials including all accessories.

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Length shall be such that number of joints are minimum. Wherever specified, to avoid longitudinal
overlaps for larger span, sheets shall be of single length and shall be site formed. Guard film should be
provided with the sheets to avoid the scratches due to handling during transportation; the Guard film
shall be removed immediately after installation of the sheets.
3.1.2 Steel Sheets
Profiled steel substrate shall be cold roll formed conforming to SANS. Base metal thickness without any
coating shall be minimum 0.6 mm with minimum yield stress 550 Mpa (SANS / ASTM A446, Grade E) as
required by consultants / Owner. On top of base steel any one of the following coatings should be
used:-
Plain Galvalume
Plain Galvalume sheets shall conform to AZ 200 of AS 1397 or ASTM 792 or SANS with hot-dip metallic
coating of 55% Al and 45% Zn alloy having total coating mass of min. 200 gms/sqm on both sides.
Galvalume with colour coating
Galvalume sheets shall conform to AZ 200 of AS 1397 or ASTM 792 or SANS with hot-dip metallic coating
of 55% Al and 45% Zn alloy having total coating mass of min. 200 gms /sq m on both sides with an
additional exterior pre-coated paint coating of Super polyester paint / PVDF paint coated with
conversion coating, corrosion inhibitive primer, final coat of Super polyester paint /PVDF paint 20
microns of selected colour on both sides, conforming to SANS or AS 2728 Type 3-4. Colour should be as
per Owner / Consultants choice.
3.1.3 Aluminium Sheets
Aluminium sheets shall conform to SANS and shall be of either troughed profiled type. Thickness shall
be as per design but not less than 0.91 mm for roof and 0.71 mm for side cladding. Surface of sheeting
shall have uniform reflective finish either plain mill or stucco embossed as per Owner / Consultants.
Surface shall be free of blemishes and have uniform gloss and brightness. Bare aluminium sheets / Pre-
coated Aluminium sheets shall be pre-painted by giving suitable paint system treatment as specified by
approved manufacturer.
3.1.4 Insulated Cladding Panels
Insulated roof / wall cladding panels shall comprise of profiled Pre coated Galvalume / Aluminium steel
exterior and interior sheets (the material of the sheet shall be as given above in clause 3.1.2 or clause
3.1.3) with rigid polyurethane foam (PUF) or expanded polystyrene (EPS) or resin bonded mineral wool /
glass wool / fibre glass roll as insulation. Density of rigid polyurethane foam shall be 35 Kg/m3 and
thermal conductivity (K) shall be 0.018 Kcal /mh0C. Minimum thickness shall be 30 mm or as specified.
PUF shall conform to SANS. Density of expanded polystyrene shall be 18 Kg/m3 and K value shall be
0.028 Kcal /mh0C. Minimum thickness shall be 50 mm or as specified. EPS shall conform to SANS.
Polyurethane/EPS outer and inner sheets shall form a composite sandwich product having high
compressive strength and wide spanning properties. If resin bonded mineral wool or glass wool or fibre

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glass roll is used as insulating material then first internal sheet shall be fixed to the structure. Then sub-
girts shall be fixed at purlin locations. Girt size will depend upon the thickness of resin bonded mineral
wool / glass wool / fibre glass roll. External sheeting shall be fixed on the sub girts. Resin bonded
mineral wool / glass wool / fibre glass roll insulation shall conform to SANS and thickness shall be
minimum 50 mm having a density of 48 kg/m3 for resin bonded mineral wool of K value 0.036 kcal /
mh0C, a density of 24 kg/m3 for resin bonded glass wool of K value 0.031 Kcal /mh0C and a density of 24
kg/m3 for resin bonded fibre glass roll of K value 0.025 KCal/mh0C. These types of insulations shall be
fixed in the cavity between the two sheets.
3.1.5 Translucent Sheets

Translucent sheets shall be of polycarbonate panels of approved make as specified by Owner /
Consultants with a minimum thickness of 2 mm and formed to match the profile of the metal sheeting
panels. Translucent sheet shall have a light transmission factor of 55% to 80% and solar energy
transmission of 25%.
3.1.6 Accessories
Materials and coatings for ridge capping, barge capping, apron flashing, cover flashing, monitors,
expansion joints and gutters shall be manufactured out of same material as roofing / cladding sheets
material and shall be shaped to match sheet profile.
3.1.7 Fasteners
Concealed fixing clips shall be used for steep sloped roof or if specially required by Owner/consultant.
Generally Steel sheets shall be fixed with Self drilling self-tapping screws with Cyclone plates (screws &
plates having coating of 45micron thickness of Zinc tin alloy & screws electroplated by cold mechanical
plating method, mesh belt furnace heat treated) or stainless-steel self-drilling self-tapping screws of
approved manufacturer with EPDM seals. If required Fasteners shall have a protective polymer coating
covering the entire fastener surface, the head as well as the shank, over zinc electroplating. Polymer
coated screws should be as per SANS or AS 3566 Class 3.
For self-drilling / self-tapping screws, high rpm (2000-2500 rpm) drivers with high amperage (47 amps)
shall be used to achieve the proper torque to secure fastening. Drill bits shall be cleared out after the
completion of drilling of sheets.
Aluminium sheets shall preferably be fixed with roof manufacturer’s requirement. Silicone sealant shall
be used for filling joints. Wind ties and bracings and special connections as per codal requirement of
SANS for coastal areas.
3.1.8 Roof Gravity Ventilators

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Aluminium / Stainless steel Roof Gravity ventilators of approved make shall be fixed in position as shown
on drawings and manufacturer’s specifications. The number of ventilators shall depend on the area and
extraction details; height of installation surrounding sheet profile.
3.1.9 Wall Louvers
Louvers shall be of units having minimum size of 1.0 m x 1.0 m with adjustable or nonadjustable
blades. Paints and colour should match side walls or as specified by Owner / Consultants. Louvers shall
include structural support members, necessary jamb trim, sealant and fasteners.
The louvers design should be such that water should not penetrate.
a. HANDLING & STORAGE AT SITE
The materials specified herein above shall be handled and stored in the manner so as not to damage the
same. The material damaged in transit, storage and erection or otherwise shall not be used and paid
for. Such damages shall be borne by the Contractor. Sheets shall be stacked on the firm and levelled
ground on wooden battens according to the approved stacking methods and /or as per instructions of
the manufacturer. Sheeting or panels shall preferably be stored with a slight inclination in longitudinal
direction to allow water that may get into the stack to drip off. Sheets shall be stored under cover
particularly when they are to be stacked for a longer period.
b. INSTALLATION & FIXING

The work shall be completed to the satisfaction of Owner/Consultant as per the approved detail
drawings and as per the instructions of the manufacturer wherever necessary and shall be approved by
the Consultants / Owner.
Sheets shall be lifted onto roof supports with ribs up. First sheet shall be fixed in position with the
female rib facing the starting edge. Female rib of the second sheet shall be lapped with the male rib of
the first sheet and shall be fixed with side lap fasteners before fastening the second sheet to supports.
Same procedure shall be followed for subsequent sheets. For side cladding same procedure shall be
followed. Minimum end lap shall be 150 mm for roof and 100 mm for side cladding. Side lap shall be
minimum 75 mm. For roof pitches below 70 end laps shall be sealed with approved silicone sealants.
Roof sheeting shall be fixed by crest fixing only. Side cladding shall be fixed preferably by crest fixing but
can be fixed by valley fixing also. In valley fixing fastener locations should be as close as possible to the
ribs. Side lap fasteners to be fixed at an interval of 350-450 mm to hold the side laps of sheets firmly in
place and to maintain a weather-proof joint. Holes must always be drilled and not punched. Extreme
care shall be taken to avoid over tightening of fasteners which will lead to deformation of sealing
washers, sheet damage and sometimes damage of the fastener threads. Fixing of flashings in masonry /

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concrete wall shall be done by applying cold applied liquid three component polyester resin base flexible
UV resistant waterproofing system of approved make laid as per manufacturer specification.
Specific workmanship shall be employed while carrying out work at laps and expansion
Joints to ensure zero leakage.
All the sheets and accessories which are found to be cracked / bend after fixing shall be replaced by
new ones. The cracked sheet so removed shall be salvaged by the Contractor by cutting into smaller but
sound lengths whenever ordered.
4. Records :
5. Reference Documents :
6. ITP Reference No :

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PLUMBING & DRAINAGE WORK

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PLUMBING AND DRAINAGE WORK

General
Plumbing Definition:
Plumbing is installed in a building not only for convenience & comfort but also for sanitation & health.
We would term the plumbing of a building to start from the water main, utilize the water in the entire
building and right up to the connecting the sewage to the municipal sewer.
General Terms
a) Static Pressure:
Pressure head in term used in fluid mechanics to represent the internal energy of a fluid due to the
pressure exerted on its container. It may also be called static pressure head or simply static head. The
static head of pump is the maximum height (pressure) it can deliver. The capacity of the pump can be
read from its Q-H curve (flow Vs. height)
b) Head in Fluid Dynamics:
In fluid dynamics, head is the difference in elevation between two points in a column of fluid, and the
resulting pressure of the fluid at the lower point.
c) Friction Loss:
Friction loss refers to that portion of pressure lost by resistance to flow exerted on fluids while moving
through a pipe, hose or other limited space.
d) Water hammer:
Water hammer is a very loud banging, knocking or hammering noise in the pipes that occurs when the
flow is suddenly turned off. It is caused by a pressure or shock wave that travels faster than the speed of
sound through the pipes, brought on by a sudden stop in the velocity of the water or a change in the
direction. It’s also been described as a rumbling, shaking vibration in the pipes.

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e) Cavitation:
Cavitation is defined as the phenomenon of vapour bubbles of a flowing liquid in a region where the
pressure of the liquid falls below its vapour pressure.
f) Air Lock:
An air lock is gas trapped in a high point of a liquid – filled pipes system. The gas, being lighter than the
liquid, rises to the highest point and restricts the flow of liquid. In very tall systems, the gas can prevent
flow entirely. Flushing the system with high flow or pressure can help move the gas away from the
highest point, or a tap/air vent valve can be installed to permit the gas to be vented.
g) Air Vent Valves:
A valve that releases air from a pipeline automatically without loss of water or introduces air into a line
automatically if internal pressure becoMSS less than the atmospheric pressure, is known as an Air Vent
Valve.
h) Pressure Reducing Valve (PRV):
When water is supplied to the flats from the overhead tank, the pressure of water increases as we go
downwards due to weight of water column above it. Thus, the pressure is maximum at the ground
floor / 1st floor and minimum at the top floor. Even in a Hydro-pneumatic system where water is
supplied directly from pump to flats the pressure is higher on the lower floors of each zone. So, the
pressures reducing Valves (PRV) is required in high rise building after every 24mtrs (80 feet) to regulate
the pressure. PRV’s also helps in reducing the water consumption by about 30%.
Acceptance of raw materials
A) G I Pipes (Internal & External Plumbing):
 G I pipe shall confirm to IS 1239 and shall bear ISI mark as well as manufacturer’s name on it.
 All concealed G I pipes shall be of class C.
 All exposed G I pipes shall be at least of class B.
 All G I fittings shall bear ISI mark as well as manufacturer’s name on it (“R” mark is preferred)
 Number of threads in G I fittings shall be minimum 11 per 1” length, pitch of threads shall be around
2.4 mm and depth of threads shall be 1.48 mm.
 Waste coupling for Wash Basin shall be half threaded with a slot for draining out overflowing water.
 Waste coupling for Sink shall be full threaded.
NOTES:
All G I pipe and fittings shall be of the diameter and size as specified on the drawing. Class of all G I pipes
shall be checked by comparing their weights as per table attached (Table 1). Colour marked on pipes
shall not be followed blindly. Wall thickness of pipes shall also be checked.

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B) C I Pipes (Internal & External Drainage):

 C I pipe shall be heavy duty, painted black at the time of delivery and shall be free from any cracks
and blow holes. Internal wall surface shall be smooth.
 Tests on CI pipes shall be carried out by checking their weights and wall thickness as per literature
provided by the manufacturer.
 All other CI pipe fittings like Collar clamps, U clamps, Single Y, Double Y, Elbows and bends shall also
be checked in a similar way. They shall be checked for proper fitting into/over the pipes.
NOTES:
All C I pipe and fittings shall be of the diameter and size as specified on the drawing or as specified by
Architect.
It is desirable always to have provisions of door type fitting at each bend (in a drainage line) and for line
laid horizontally provision of cleanouts are kept before the branch connections, bends and at specific
intervals of 6
metres.
C) PVC Pipes (Internal & External Plumbing and Drainage):
Concealed PVC pipes shall withstand a pressure of 6 Kg/cm² and exposed PVC pipes shall withstand a
pressure of 4 Kg/cm²
NOTES:
All PVC pipes and fittings shall be of the diameter and size as specified on the drawing or as specified by
Architect.
It is desirable always to have provisions of door type fitting at each bend (in a drainage line) and for line
laid horizontally provision of cleanouts are kept before the branch connections, bends and at specific
intervals of 6 mitres.
D) CPVC Pipes (Internal & External Plumbing):
CPVC pipes shall be visually inspected for any cracks or defects. Plastic clamps from the same
manufacturer should be preferred as far as possible. Metal clamps for CPVC pipes should be avoided.
NOTES:
All CPVC pipes and fittings shall be of the diameter and size specified on the drawing or as specified by
Architect.
For all pipes other than G I, manufacturer’s test certificate for following tests for pipes shall be obtained
and properly filed in at site, for easy reference:
 Hot water pressure test
 Pigment dispersion & physical dimension test

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 Reversion test
 Impact test
 Melt flow index test
E) PPR Pipes (Internal Plumbing):
All PPR pipes received on site shall be free from cracks and other defects. PPR Fittings, Bends, Elbows
shall be of approved make and pressure class PN 20/PN25
F) Concrete Pipes (External Drainage):
1) RCC Hume pipes of class NP2 shall be used for normal use and Hume pipes of class NP3 shall be used
for road crossings with vehicular traffic.
2) Concrete pipes shall be beveled end type or spigot and socket type, provided with collars as per
specification or as indicated on drawing. If collars are provided, it shall be ensured that pipes are
delivered with appropriate numbers of collars. Pipes delivered without collars shall not be accepted.
3) Pipes showing cracks and which are damaged during transport shall be rejected.
4) Joint line on pipes shall be as thin as possible.
G) STONE WARE GLAZED Pipes (External Drainage):
SWG pipes shall be checked for any cracks or defects before acceptance.
H) Gully Traps (External Drainage);
1) Gully traps shall be of size 150 x 150 or as specified.
2) On receipt at site, they shall be filled with water completely and kept overnight for checking leakages,
if any. Faulty Gully traps shall be discarded and not used anywhere.
I) Inspection Chamber Covers (External Drainage):
Inspection chamber covers shall be of Concrete or C I (Heavy duty/Medium duty/Light duty) and
dimensions as specified on drawings or as specified by Architect.
J) BRICKS (External Drainage)
The quality of bricks should be as mentioned in Masonry Method Statement.
K) Other Fixtures
(Internal Plumbing):
Other fixtures like Nahani Traps, WC Traps, Bottle Traps, EWC, wash Basins, Sinks, Anti Siphon pipes,
other WC fittings etc. shall be checked for any cracks, defects etc. Their size, shape and make shall be as
shown on the drawings or as mentioned in the specifications.
(External Plumbing):

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 Other fixtures like Pressure reducing valves, Gate valves, Foot valves, G I spout, Clamps for pipes etc
shall be checked for any cracks.
 Their size, shape and make shall be as shown on the drawings or as specified by Architect.
L) Sealants:
 All sealants shall be of approved make.
 Teflon tape shall be used as a thread sealant for GI / CPVC pipes.
 Lead / Drip seal shall be used for jointing of CI pipes or otherwise specified by Architect.
 “Habak”, “Tag”. “Hold tight” shall be of approved make.
 For jointing of CPVC pipes and fittings, one step / twostep solvent cement with primer as
recommended by the CPVC pipe manufacturer / as specified by Architect shall be followed.
Class Identification for GI Pipes (Table: 1)
SIZE Diameter of Pipes
In mm 15 20 20 32 40 50 65 80 100 125 150
In Inch ½” ¾” 1” 1 ¼” 1 ½” 2” 2 ½” 3” 4” 5” 6”
TYPE Wall thickness of G.I. Pipes in mm
Light Class 2 2.35 2.65 2.65 2.90 2.90 3.25 3.25 3.65 -- --
Medium Class 2.65 2.65 3.25 3.25 3.25 3.65 3.65 4.05 4.50 4.85 4.85
Heavy Class 3.25 3.25 4.05 4.05 4.05 4.05 4.05 4.85 4.85 5.4 5.4
TYPE Weight of G.I. Pipes ( kg / metre length)
Light Class L
mark ( Yellow 1.01 1.18 2.10 2.72 3.40 4.32 6.10 7.20 10.48 -- --
Mark )
Medium Class
M mark ( Blue 1.28 1.65 2.54 3.27 3.76 5.31 6.81 8.85 12.68 17.04 20.20
Mark )
Heavy Class H
mark ( Red 1.51 1.97 3.08 3.97 4.58 6.38 8.20 10.51 14.97 18.64 22.2
Mark )
The whole system is classified into following:
 Internal plumbing & internal drainage
 External plumbing
 External drainage
Procedures

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A) Internal Plumbing and Internal Drainage:

Pre-Installation Procedures (internal plumbing / internal drainage works):
1) A licensed plumber shall be employed to carry out all plumbing works and a Photo Copy of his license
shall be kept ready for producing before any authorized agency coming for inspection.
2) It shall be ensured that base coat of toilet water-proofing is complete before staring any of the
following procedure.
3) It is necessary to have ledge walls for RCC shear walls for concealed plumbing network and the base
coat waterproofing should be necessarily done before laying of ledge walls.
4) Toilet walls shall be clearly marked with proposed tile locations (using nylon string dipped in white
colour solution) showing tile joints, routing pipelines over walls, locations of fittings and proposed outlet
of pipes. (Concerned architectural drawing showing exact distances from walls and finished floor level
(FFL) of toilet, shall be referred to while doing so and the drawing shall be kept ready for inspection).
Slight adjustments in pipe routing, if required, shall be made on site with consent of Site In charge for
keeping outlets of pipes at joints.
5) Finished tile plane shall be clearly marked on walls by fixing tile pads at four corners of walls.
6) Dado tile piece, if required, shall be kept at corner or at a place which is not easily detected.
7) Similarly, toilet floor shall be marked with correct position of sanitary-ware including bath tub fittings
and piping.
8) Flush tanks / Boiler or heater / Wash basin positions shall be marked on the walls.
9) Drainage outlet holes shall be clearly marked on walls, hole size being same diameter as that of outlet
pipe. Holes shall not be made in cast RCC members. Sleeves shall be planned and kept at the desired
location at the time of cast.
10) Ablution tap position shall be kept on right hand side unless specified otherwise on drawing.
During Installation Procedures (internal plumbing / internal drainage works):
1) Chasing of Brick-work shall start only after marking on Walls / Floors is approved.
2) It shall be ensured that all pipes / fittings / sanitary-ware / sealants etc. are as per approved brand /
as specified by Architect.
3) Sufficient lighting arrangement shall be provided for working in dark areas.
4) Chasing in masonry shall be done with the help of cutter machine and depth of groove in walls shall
be 15mm more than diameter of pipe to accommodate mortar and plane of cutting shall be parallel to
routing of pipeline. Within the chased portion light hammering shall be allowed, if it doesn’t cause harm
to masonry.

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Installation of G I Pipes:
1) G I Pipes shall be cut to the required length as per layout on walls / floors and coconut oil shall be
used while threading.
2) Pipes shall be cut at perfect right angles and burrs, if any, shall be removed by debarring tool.
3) Number of threads in G I Pipes shall be minimum 11 per 1” length, Pitch of threads shall be around
2.4mm and depth of threads shall be 1.48mm.
4) Teflon tape shall be used as a sealant over threads while jointing pipes.
5) Concealed G I pipes including fittings shall be applied 2 coats of bituminous paint (Black Japan) before
installation. Asbestos rope OR alternative shall be tied around hot water pipes and Hessian cloth shall be
tied around cold-water pipes. Over this, a coat of bituminous paint shall be applied for better protection
against corrosion.
NOTES:
For heat insulation it is recommended preferably to use poly – urethane pipe sleeves or use 2-3 mm
thick heatlon sheets. However, the instructions given by Plumbing Consultant / Architect should be
followed
6) All G I fittings shall be washed with kerosene to remove rust inside, prior to their installation. Fittings
shall be fitted using “Habak” and “Teflon” tapes only.
7) The pipe assembly shall then be placed in chases.
8) Horizontal pipelines shall be laid perfectly horizontal and vertical pipelines shall be laid perfectly
vertical. Slant piping shall be avoided.
9) To keep G I lines in position 40 mm plumbing nails at 9” c/c on alternate sides of G I pipes shall be
driven in masonry.
10) Flushing lines shall be of minimum dia 1 1/4” and shall be separated from fresh water lines entirely.
All pipelines through which gravity flow is expected shall be laid with a minimum slope 1:100 or
specified on drawing.
11) All outlets shall be maintained at right angles and fitted with G I plugs. G I plug shall project at least
½” beyond the face of plaster for fixing of fittings.
12) Open G I pipes shall be applied with oil paint as an anti-corrosive treatment over a base coat of red
oxide primer.
13) Whenever pipes are embedded, insertion depth shall be marked on pipes.
14) All the open pipes shall be properly plugged in to prevent entry of mortar in pipes and also for
carrying out Pressure Test.

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15) Control valves shall be provided for each toilet unit and valve position shall be easily accessible for
operating through toilet window, if possible.
16) Fittings for mixer unit in toilet shall be installed carefully so as to avoid mixing of hot water and cold
water.
17) Mouths of traps shall be plugged with suitable cloth to prevent entry of dirt and mortar into it.
Post Installation Procedures (internal plumbing / internal drainage works):
1) After complete erection of pipeline and plugging open ends, flushing of entire pipeline shall be carried
out by keeping only one of the pipe fitting open. Pressure test shall then be carried out using pump and
calibrated Pressure Gauge for minimum pressure of 10 Kg/cm² (or 1 ½ tiMSS the design pressure,
whichever is greater) by fully charging the entire section and keeping it pressurized for a period of at
least 30 minutes. During this period no leakage should be observed and pressure drop should not be
more than 0.3 bars
2) If leakages are observed during Pressure Test, necessary repairs shall be carried out and Pressure Test
shall be carried out again.
3) After the pressure test is successfully carried out, chases as well as holes shall be filled with non shrink
grout and the grout shall be cured for at least 3 days.
Note: in case, pipes other than G I are used, technical literature and Manufacturer’s user Guide Manual
shall be made available on site.
Installation of CPVC pipes:
Manufacturer’s Installation Instructions shall be referred to during installation of CPVC pipes. However,
for general guidelines, refer to special requirements.
Special Requirements:
1) Pipes shall be cut to the required length using sharp edges cutter to have a square cut exactly
perpendicular to the pipe which provides maximum bonding area for the joint.
2) If cracks are observed during cutting, then the pipe shall be cut 50 mm beyond the crack and such cut
piece of pipe shall not be used anywhere.
3) Chamfering tool, file or pocketknife shall be used to give slight bevel at the cut end for easy entry of
pipe into the fittings. Burrs, if any, shall be removed with the help of debarring tool.
4) Pipes shall be wiped clean and made dry before installation of fittings.
5) PVC pipes should be embedded with proper encasing for internal drain to prevent damages, cracks
etc.

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NAME:
Application of two step solvent cement for jointing:

1) Application of Solvent Cement shall be done in well-ventilated area.
2) The exact position of fitting shall be marked on the pipe surface as well as on fitting surface.
3) Primer recommended by pipe manufacturer shall be applied to outside of pipe and inside of fitting.
4) After the pipe surface becoMCS tacky, a thin even coat of solvent cement shall be applied to inner
face of fitting and a thicker even coat shall be applied to outside face of pipes. Solvent Cement shall be
as recommended by the manufacturer of pipes.
5) Immediately after application of Solvent cement (i.e. Solvent Cement is still wet), pipe shall be
inserted in the fitting by rotating ¼ to ½ turn while pushing, to ensure even distribution of cement within
the joint.
6) Fitting shall then be held in correct position for about 10 seconds, till an even bead of Solvent Cement
is visible around the joint. If the bead is not continuous, it indicates that adequate Solvent Cement was
not applied.
7) Solvent cure time is 1 Hr for 1/2” to 1” dia pipes and 2 Hrs for 1 ¼” to 2” dia pipes or as recommended
by manufacturer.
8) Adequate safety measures shall be taken as per pipe manufacturer’s recommendation, while applying
solvent cement.
9) After assembly the pipe section shall be placed in masonry chases at correct positions and clamped
with plastic clamps (supplied by the pipe manufacturer) at 900 mm c/c for pipe dia less than 1” and 1200
mm c/c for larger pipe dia.
10) Masonry surface shall be smooth and without sharp edges around the pipes.
11) The entire pipe system is then Pressure Tested by first blowing out all air within and then filling it
with water completely. Applied Pressure and time for testing shall be as per recommendation of the
CPVC pipe manufacturer. During Pressure Testing no leakages should observed. If leakages are
observed, concerned pipe sections shall be replaced with new ones.
For application of one step solvent cement primer application is not required.
PPR Pipes:
For PPR pipes general guidelines given for CPVC pipes shall be followed. Polyfusion Welding Device with
Mortice shall be used for welding of PPR pipes and Teflon Tape shall be used as a sealant for threads.
Heating, Welding and Cooling time shall be as recommended by the manufacturer.
Fixing of Nahani Trap:
1) Nahani Trap shall be fixed along with water-proofing works.

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2) Top level of Nahani trap should match with finish coat of water-proofing i.e. bottom level of flooring
above.
3) Nahani Trap shall be fixed with minimum 15 cm from side walls.
Fixing of Wash Basin and Sink:
1) Top level of Wash Basin shall be checked w.r.t. FFL as per Architectural Drawing
2) Waste coupling for Wash Basin shall be half threaded with a slot for draining out overflowing water
and waste coupling for sink shall be full threaded.
3) All Wash Basins and Sinks shall be provided with bottle traps before connecting to drain pipes.
Anti-siphon pipe:
All WC fittings shall be connected to external Anti siphon pipe.
Joinery:
1) WC Trap connector:
a) PVC pipe shall be used as WC Trap connector
b) Lip ring with rubber lubricant shall be fitted over spigot portion of ceramic trap.
c) Over lip ring, PVC pipe connector which acts as socket shall be fitted.
2) PVC to PVC joint:
a) PVC pipe shall be cut with the help of toothed saw
b) 1/3rd thickness of pipe (spigot) shall be given a chamfer at 15º using coarse file.
c) Both spigot and socket shall be cleaned thoroughly.
d) Marking shall be made on spigot up to which joinery is required.
e) Joining lubricant shall be applied on spigot from marking to chamfered end and a rubber ring shall be
fixed over it, without twisting.
f) Spigot is then inserted into socket to 10mm less than the marking to allow for thermal expansion.
3) PVC to CI joint:
a) Inside face of PVC plug tee socket shall be roughened with emery paper and a thin coat of solvent
cement shall be applied over it with the help of brush.
b) medium size sand is then sprinkled over it and allowed to dry for 5 minutes which will provide a
better bonding surface.
c) Gap between Nahani Trap and PVC plug tee shall then be filled with cement.
4) CI to CI:

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For CI-to-CI connections, lead joints / drip seal joints should be used or as specified in drawing. Smoke
test shall be done after all the joints are filled & the branches brought up to ground level.
1) In C.I. pipes with lead joints the joints shall be first caulked with strands of spun yarn. The requisite
quantity of lead shall be poured / caulked into the joint & then shall be compacted by means of special
tools having chamfered edges & angled length.
2) In drip seal joint, two component epoxy-based chemical is used instead of lead.
B) External Plumbing
Pre-Installation Procedures:
1) A licensed plumber shall be employed to carry out all plumbing works and a Photo Copy of his license
shall be kept ready for producing before any authorized agency coming for inspection.
2) Approved plumbing drawing shall be made available on site.
3) For CPVC pipes, technical literature and manufacturer’s user guide manual shall be made available on
site 4) Layout of pipes shall be marked on external wall surface as also on terrace and shall get approved
from plumbing consultant. It shall be ensured that vertical lines so drawn are in plumb.
5) Holes shall be made in parapet wall. Diameter of holes shall be 1” more than the respective diameter
of pipes.
6) In Over Head Water Tank and Under Ground Water Tank GI pipe sockets shall be provide as inserts at
the inlet / outlet locations to avoid puncturing of RCC walls later.
During Installation Procedures (External plumbing):
Installation of GI Pipes:
1) GI pipes shall be cut to the required length as per layout on walls and terrace. Coconut oil shall be
used while threading.
2) Pipes shall be cut at perfect right angles and burrs, if any, shall be removed by deburring tool. Round
wheel cutter OR cutter recommended by manufacturer shall be used for cutting CPVC pipes.
3) Number of threads in GI pipes shall be minimum 11 per 1” length, Pitch of threads shall be around
2.4mm and depth of threads shall be 1.48mm.
4) All GI fittings shall be washed with kerosene to remove rust inside, prior to their installation.
5) Fittings shall be fitted using “Habak” and “Teflon” tape only while jointing pipes.
Vertical pipes shall be laid truly vertical by checking their plumb. Horizontal pipelines shall be truly
horizontal. Slant piping shall be avoided.
6) Adequate distance shall be maintained between main pumping lines and wall surface for
maintenance purpose.

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7) Vertical pumping mains shall be double clamped near joints, connections, bends and turns to avoid
bursting of pipes.
8) Clamps for CPVC pipelines shall be of plastic or PVC as specified by manufacturer. (Metal clamps shall
be avoided). Clamps for vertical CPVC pipelines shall be kept loose for free movement of pipes near
expansion loop, if specified. Expansion loop shall be adequately supported.
9) Entry of pipes through walls shall be at right angles.
10) Pressure reducing valves shall be provided for high rise buildings and Control valves shall be
provided for each branch line of OHWT. Control valve position shall be easily accessible for operating
through toilet window, if possible.
11) Foot valve location shall be kept 4” - 6” above tank bottom / sump level. Non return valves shall be
provided near pumps.
12) Vent pipes shall be provided for all outlets through OHWT to prevent air locks.
13) Cleanout provision at bottom shall be provided for each line separately.
14) Pipeline on terrace shall necessarily run along parapet and be properly anchored to parapet wall
with the help of saddles / clamps.
15) Underground main GI pipeline including fittings shall be applied 2 coats of bituminous paint (Black
Japan) before installation and shall be preferably supported on concrete pedestals.
16) In case internal piping network is to be connected to outside water supply lines of different material,
suitable adapters with sealants shall be used. Refer joinery at the end of this section.
17) Open GI pipes shall be applied with oil paint as an anti-corrosive treatment over a base coat of red
oxide primer.
18) Exterior grade latex paint shall be applied on CPVC pipes for UV resistance.
19) In case, solar water heating system is provided, temperature control system shall be installed and
adequate precaution shall be taken to avoid mixing of hot and cold water. Also, GI hot water pipes shall
be wrapped with wool piles and Aluminium foil for which minimum 1” clear distance between wall and
pipe surface shall be kept.
Post Installation Procedures:
1) After complete erection of pipeline and plugging open ends, flushing of entire pipeline shall be carried
out by keeping only one of the pipe fitting open.
2) Gravity pressure testing shall then be carried out by completely filling the entire pipeline with water
for 24 hrs and leakages through pipelines, if any, shall be observed.
3) If leakages are observed during Pressure test, necessary repairs shall be carried out which may involve
replacing part of pipeline. Pressure testing shall then be carried out again.

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4) After the pressure test is successfully carried out, holes in masonry shall be filled with non-shrink
grout and the grout shall be cured for at least 3 days.
Installation of CPVC pipes, application of two step solvent cement & joinery:
Same as mentioned in internal plumbing & internal drainage.
Checks and precautions on UGWT:
1) Injection grouting and box type waterproofing shall be done.
2) Waterproof plaster shall be applied to sides and bottom of tank from inside. Care shall be taken to
provide chamfers at the junction of side walls and bottom slab. Waterproofing slope shall be provided
towards sump.
3) Waterproofing of top slab shall also be carried out.
4) Other check points shall be
i) Provision of sump for fixing submersible pump as well as for collecting water and cleaning.
ii) Position of inlets and outlets as per drawing.
iii) Provision of adequate no of manholes.
iv) Sizes of manholes are proper and covers are in properly openable condition.
v) Provision of rungs as monkey ladder near manholes for large tanks.
vi) Inlet and Outlet pipes should be positioned and fixed with reinforcement before concreting.
Checks and precautions on OHWT:
1) Internal waterproofing of tank shall be carried out in the same way as described for UGWT.
2) Slope of internal base water proofing shall be towards outlet pipes.
3) Other check points shall be
i) Provision of compartment wall for drinking water, flushing water and fire water and separate outlet
for each.
Control valve for each outlet near the tank.
ii) Separate colour for above outlet pipes.
iii) Provision of ball valve and automatic water level indicator.
iv) Provision of overflow pipe which shall be connected to top terrace down take pipe.
v) Provision of wash out pipe.
vi) Provision of access to top with peripheral walkway with hand railing.
vii) Sizes of manholes are proper and covers are in properly openable condition.

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viii) Provision of rungs as monkey ladder near manholes for large tanks.
C) EXTERNAL DRAINAGE
Pre-Installation Procedures (External drainage works):
1) A licensed plumber shall be employed to carry out all plumbing works and a Photo Copy/Xerox copy
of his license shall be kept ready for producing before any authorized agency coming for inspection.
2) Approved plumbing drawing showing routing pipeline, location of Inspection Chambers and all
necessary Invert levels shall be made available on site.
3) Layout of sewage and sullage shall be marked on external wall surface and shall get approved from
plumbing consultant. It shall be ensured that vertical lines so drawn are in plumb.
4) Sleeves shall be kept in toilet / bath-room walls or holes shall be drilled in walls for connection to
sewage and sullage lines. Diameter of sleeves / holes shall be 1” more than the respective diameter of
outlet pipes. (Drilling of holes in RCC structure is not permitted).
5) In Septic tank, PVC pipe sleeves shall be provided as inserts at the inlet / outlet locations to avoid
puncturing of RCC walls later.
During Installation Procedures (External drainage works):
Sewage and Sullage:
1) All Sewage as well as Sullage lines shall be of Heavy-duty CI or PVC and connections to them shall be
by plug fittings.
2) Where municipal drainage lines are not provided, sewage lines and Sullage lines are kept separate.
Sewage lines shall first be connected to septic tank and then further to soak pit whereas sullage lines
shall directly be connected to soak pits. (Reference shall be made to approved drainage drawings).
3) Where municipal drainage lines are provided, both Sewage and Sullage can be collected through a
single pipeline and then directly connected to Municipal sewer lines. OR Sewage lines shall be taken
separately along the walls and then both connected to Municipal sewer lines. (Reference shall be made
to approved drainage drawings).
4) Vertical stacks (Sewage / Sullage) shall be clamped on both sides of the joint. Clear minimum distance
of 100 mm shall be kept between pipes and wall.
5) If PVC pipes are used as vertical sewer lines, last two pipes shall be of C I.
6) Anti-siphon lines shall be provided for buildings of height more than 15 metres and shall be directly
connected to water closets. Their direct connection to sewage lines shall be avoided.
7) Sewage lines as well as Anti-siphon lines shall be carried to height, at least 6’ above terrace top and
shall be provided with vent cowls.

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8) Vent cowls shall be provided with mosquito nets.

9) Both Sewage and Sullage lines, after fixing to wall should appear truly vertical when observed visually
and their connections should be symmetric. Criss-cross connections shall be avoided.
10) All sullage lines shall first be connected to Gully Traps. Gully Traps shall be built inside Brick Masonry
which is plastered afterwards.
11) Inspection chambers in Burnt Brick Masonry shall be constructed at exact location as per drawing
with covers at top.
12) Invert Levels shall be checked with the help of Auto level and got approved from the Engineer. Level
tube shall not be used for fixing invert levels.
13) Chambers shall be plastered, both from inside as well as outside.
14) All branch lines shall join main sewer in the direction of flow sewage. Also branch lines joining
Inspection Chambers shall not be at angle greater than 45_, with the direction of flow of sewage.
15) Inlet / Outlet of chambers shall be plugged with cloth to prevent entry of debris inside. Such
plugging shall be kept till complete erection of drainage line and till pressure testing starts. PCC is
essential underneath chamber.
16) Heavy duty chamber covers shall be used on roads and parking, whereas Light / medium duty
chamber covers shall be used at other places.
17) Channelling inside chambers shall be done smooth or half round SWG pipes shall be used for the
same, if specified by Architect. Chambers, especially at curves shall be properly attended to for providing
smooth curves finished surface inside for smooth flow of sewage within.
18) RCC pipes shall be used for connecting Inspection Chambers. It is ensured that minimum earth
cushion over pipes is 450mm pipes shall be adequately supported underneath by concrete and
minimum slope of 1:100 shall be maintained through the length of sewer line.
19) Inspection Chambers shall be located as near as possible to Gully Trap locations and connection from
Gully Traps to Inspection Chambers shall be through SWG pipes.
20) Jointing of RCC / CI / SWG pipes shall be done with cotton yarn (packing rassi) and expansive grout
and finished with neat cement from all sides. Joints shall then be covered with wet Hessian cloth and
cured for at least 4 days.
21) During jointing operation, C I and SWG pipes shall be supported with masonry supports, whereas
RCC pipes shall be supported by at least two concrete blocks supports to avoid failure of joints.
22) Intermittent ventilation shall be provided for the drainage line as indicated on drawing.
23) Always provide a gas vent for the first & last inspection chamber.
24) In a sewer line a vent shaft should be preferably fixed after every 150 mtrs.

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25) A drop arrangement should be done whenever there is difference of 600mm or more in the invert
levels.
26) It is recommended to do bed PCC at the required gradient before laying of the drain line & the line
should be encased properly and proper gradient & alignment is maintained, verified & jointed
satisfactorily.
Post Installation Procedures (External drainage works):
1) After erection of drainage line, all Inspection Chambers and Gully trap as well as Nahani / P traps of
toilets shall be cleaned off mortar, debris and other accumulated construction material.
2) Acid cleaning shall then be carried out from top floor to bottommost floor.
3) Inlet / Outlets of Inspection Chambers shall then be unplugged and entire drainage line shall be filled
with water under pressure.
4) If any leakages are observed, the same shall be rectified. Rectification may involve complete removal
of defective part of drainage line.
5) The drainage line shall then be pressure tested again for ensuring total leak proof flow along the
entire drain line.
6) All holes in masonry shall be rendered with non-shrink grout.
7) Backfilling shall start only after satisfactory testing of drainage line. Backfilling shall be done in layers
with good soil, layers not exceeding 1’ at a time and well compacted by watering soil, if required.
Precaution shall be taken so as not to leave voids below pipes.
Rain Water Drainage:

1) Rain water drainage shall be either C I or PVC or as specified by Architect.
2) Marking of rain water pipes shall be done on external wall surface as per drawing.
3) Outlet positions on terrace shall be marked and holes drilled accordingly.
4) Rain water pipes shall then be fixed along walls so that they appear vertical when observed visually.
5) Clamping and jointing of CI pipes shall be done as specified for sewer down take whereas clamping of
PVC pipes shall be done with PVC clamps at every 6’ along the pipe.
6) Care shall be taken during clamping so as to keep at least 1” gap between plastered wall surface and
pipe surface.
7) Rain water down take pipe shall be terminated at least 9” above finished ground level and provided
with a 45º shoe at bottom end and PVC strainer at top inlet position. Also a tee shall be provided at top
for cleaning purpose.

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8) All rain water shall be provided with a concrete block support at bottom end.
9) All holes in masonry shall be rendered with non-shrink grout.
10) A separate drain shall be constructed as per drawing to collect rain water and dispose it into rain
water harvesting system or adjacent nallah or as specified by the architect.
Joinery:
PVC to PVC joint, PVC to C I joint & Open CI to CI joint - Same as mentioned in internal plumbing &
internal drainage.
NOTES:
However, it is necessary to follow the Plumbing Consultant’s drawings and instructions. But for general
guidelines, the following dia. of pipes is recommended for the following.
1) Soil Waste -100 to 150mm
2) Waste Water - 75 to 100mm
3) Gas Vents & Anti-syphonage - 50 to 75mm
4) Rain Water - 90 to 200mm
Internal Plumbing & Internal Drainage:
Position of: WHB, EWC, Bath tub, Flush tank, As per Architectural Drawing
Boiler w.r.t. FFL and walls.
Fixing of MS painted brackets of WHB Anchor fasteners used
Position of Nahani Trap At WHB outlet and at least 15cm clear from wall
Fittings and fixtures Satisfactory fitting
Holes / Chases in Masonry Rendered with non-shrink grout
All traps Position and level as per Architectural Drawing
Functioning of: Water flow found satisfactory with enough
Ablution tap, Angle stop cock, Long body bib cock pressure
(Kitchen sink), Dry balcony bib cock, Mixer
shower, Flushes, Basin pillar, Basin mixer cock,
Nelson valve, Control valve
All above taps checked after locking No leakages observed
Pressure Testing Satisfactory

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External plumbing:
External pipelines Truly vertical when observed visually with
adequate distance between wall face and pipes
Pipelines on terrace Along parapet wall and clamp with saddles
Pumping mains Double clamp near joints, bends and turns
Provision of control valves For each outlet near OHWT
Position of foot valve 6” – 8” above tank bottom of UGWT
Manhole cover for UGWT & OHWT Double seal cover type with facility for locking
Leakage observed during gravity pressure testing Corrected and no leakages observed in next
pressure test
Access for water tanks and duct for maintenance Easy
Clamps for CPVC pipes Plastic or as specified by Architect
Fitting of clamps for CPVC pipes Loose for allowing free movement
Rendering of holes in masonry With non – shrink grout
External Drainage:
Clamps Not broken and spacing as specified
For vertical PVC sewer lines Last two pipes in CI
Jointing of pipes As specified
Bottom of rain water pipe Provided with 45º shoe and at least 9” above
finished ground level.
Alignment of sewer/rain water pipes along walls. Truly vertical when observed visually
Access to main ducts Easy
Removal of pipes for maintenance Easy
Vertical sewer lines Taken at least 6’ above terrace level and provided
with cowls
Vent pipe above septic tank Taken at least 6’ above top slab level

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Rain water pipes Provided with concrete block underneath

Anti-siphon pipe Directly connected to water closets
Leakages Not observed
TOOLS:
A. Drill, Chasing Machine, Spirit Level, Hammer, Drill Bit, grinding wheel, File, Measuring tape,
Pressure Testing Machine.
B. Chisel, Pipe wrench, Chain wrench, sledge hammer, screw driver, Bench Vice, pipe vice, Die set,
hammer drilling M/c, Mini
C. angle grinding M/c.
Records :
ITP Reference No :

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CONDUTING WORK
CONDUITING

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1 SCOPE
This procedure covers erection installation /laying, testing & commissioning of PVC Conduits.
2 PURPOSE
The purpose of this procedure is to provide guidelines for laying of PVC Conduits.
3 REFERENCE DOCUMENTS
1. CONTRACT SPECIFICATIONS.
2. APPLICABLE CODES AND STANDARDS
3. QA PLAN FOR CONDUITING
4 APPLICABILITY
This procedure is applicable for Conduit laying in slab, walls & beams.
5 PROCEDURES
1. RECEIPT AND STORAGE OF CONDUIT:
a. Soon after receipt of conduit inspection shall be carried out to confirm quality, quantity and
size of conduit.
b. Physical verification conduit shall be done to check for any damages.
c. Conduits shall be properly stacked size wise in stores

d. Identification tags shall be provided at every stack.
2. PRE-INSTALLATION
a. Shop drawings shall be prepared on the basis of layout drawings and it shall be get approved
from Architect / Client.
b. Before laying the conduit, approaches shall be made available to reach to site.
c. Ensure the completion of reinforcement and shuttering & works
d. Before laying of conduits location of beams and wall shall be checked as per drawing.
3. INSTALLATION
a. Marking of conduit layout as per the drawing shall be done.

b. After marking proper size of conduit shall be selected as per drawing. Conduit shall be properly
laid as per route. Coupler shall be provided at the joint of two conduits with solvent cement.
c. Bending of conduit shall be done with bending spring to the required angle.
d. All the junction boxes for fixture shall be fixed as per the drawing
e. All the vertical drops in beam shall be put as per wall location.

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f. After laying, conduits and accessories shall be tied with reinforcement by means of binding
wires.
g. All the junction boxes shall be sealed with gunny bags to avoid entry of concrete.
h. Red oxide shall be provided surrounding the junction boxes to get the location of junction box
after removal of shuttering.
i. Proper distance shall be maintained between Electrical & Communication conduit as per
specification.
j. Conduits that are routed ahead of no concreting area shall be marked with circuit Nos with
paint.
k. All the required measurements shall be taken before concreting for preparation of “As Built
drawings”.
Necessary records in various stages of work shall be maintained as per the following format:
Check List for Conduiting:
Records :
ITP Reference No :

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METHOD STATEMENT
FOR
INSTALLATION TESTING &
COMMISSIONING OF INTERNAL WIRING

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INSTALLATION TESTING & COMMISSIONING OF INTERNAL WIRING
1.0 SCOPE
This procedure covers erection, testing & commissioning of wiring
2.0 PURPOSE
The purpose of this procedure is to provide guidelines for pulling of wires.
3.0 REFERENCE DOCUMENTS
1. CONTRACT SPECIFICATIONS
2. APPLICABLE CODES AND STANDARDS - IS: 732
3. QA PLAN FOR WIRING:
4.0 APPLICABILITY
This procedure is applicable for all the buildings wiring.
5.0PROCEDURE
1. RECEIPT AND STORAGE OF WIRES:
a. Soon after receipt of wires inspection shall be carried out to conform quality, quantity and size of
wire.

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b. Physical verification wires shall be done to check for any external damages.
c. Wires shall be properly stacked size wise/ colour wise in stores
d. Identification tags shall be provided at every stack.
2. PRE-INSTALLATION
a. Conduit shall be made free from any blockages by pulling cord
b. Proper size of wire and colour of wire shall be selected.
3. INSTALLATION
a. Wire shall be pulled with help of G.I. wire. Sufficient quantity of wire shall be kept at both
ends for termination.
b. Wire shall be terminated at DB end with proper size of lugs. Ferruling shall be done to
identify the circuit.
c. Earthing shall be done with green 1.5 Sq.mm for wire all fixtures, fans & sockets. Earth wire shall be
terminated at earth strip at DB end and at earthing terminal at fixture / fan end.
Necessary records in various stages of work shall be maintained as per the following format:
Records :
ITP Reference No :

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METHOD STATEMENT FOR STEEL

STRUCTURE FABRICATION & SITE
INSTALLATION WORK
STEEL STRUCTURE FABRICATION & SITE INSTALLATION WORK

1. OBJECTIVE

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The scope of these procedures covers the:

 Fabrication and installation as per the approved drawings;
 Fabrication of Steel Structures (Section A)
 Surface preparation
 Painting
 Erection of Fabricated Steel Structures. (Section B)
Purpose
To ensure that all phases of steel member’s Fabrication and erection are managed as per Technical
Specifications and Client requirements.
1.2 Responsibility
Six Construct is responsible for obtaining required authority approvals and execute the works to
comply with project quality and safety standards.
This section is intended to clearly define the responsibilities and communication procedure
between all the key personnel involved in the activities.
Project Manager
 Is responsible for the overall project activities;
 Is responsible for the Production activities related to the scope of work;
 Is responsible to arrange the work force, machinery and equipment required for the set
production targets;
 Is responsible to monitor and assure the material availability for erection activities;
 Is responsible to plan the work force and material requirement for production in coordination
with site engineer and erection superintendent responsible, to generate and update the
erection status, calculate and estimate the costs and budgeting and to arrange the materials
required for fabrication;
 Is responsible to provide weekly production reports to the main contractor project manager;
 Ensure project erection the targets are well maintained in terms of quality & quantity
requirements;
Site Superintendent.
 Responsible for erection and the day-to-day site activities, in organizing and handling of manpower
and equipment’s in order to achieve the required performance output both in terms of quality and
quantity within the hours worked for the project;

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 To carry out specifically the instruction given by the Project Manager and ensure that the work being
carried out is in accordance with company procedures and also that safety regulation is observed by
the men under his control;
 To ensure that the workforce under his control, report to work punctually and carry out the work
efficiently without any obstructions;
 Ensure the fabricated steel members issued to site are handled with proper care and secured safely
while offloading from and to site. Special care shall take to prevent deformation and paint damages
while site handling;
 Coordinate with mechanical draftsmen for better understandings prior start erection activities;
 Coordinate with QA/QC before and after erection stages to ensure proper execution in terms of time
and quality of work;
 Report to the project manager.
Site Supervisor / Foreman;
 Conduct daily tool box talks (TBTs);
 Control, monitor and Implement safety inductions corroborated with Site safety officer;
 Control and monitor regularly the lifting equipment’s: visual inspection to assure its qualities the
integrities of each of the following: lifting belts, shackles, lifting chains, eye bolts, chain pullers etc.;
 Supervise and monitor the erection process full time;
 Guide the riggers to ensure that are using proper signals, with respect to crane operators and steel
erectors;
 Plan in advance the required erection equipment’s: mobile cranes, fork lifters, man lift and etc.
 Read, interpret, follow / implement the approved drawings related to Erection activities corroborates
with Shop drawings;
 Follow and implement strictly the project Approved procedures;
Report all incidents and accidents to the project stakeholders;
 Coordinate with QA/QC before and after the fabrication stages;
 Report the daily production status to fabrication coordinator;
 Request Coordinate with site surveyor for installed steel structure components from site
representatives;
 Generate RFI to QA/QC department for all online and final inspection.
QA/QC Engineer;
 Maintain the quality level of the company and its product;
 Involved in developing systems to ensure products or services are designed and produced to meet
or exceed customer requirements and expectation;
 Responsible to prepare project Quality Plan, Inspection Test Plan and other project documents.

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necessary client submittal for review and approval;

 Coordinate with approved TPI for material inspection whenever is applicable;
 Responsible for all Quality Control Inspections of fabrication and erection works;
 Coordinate with welding TPI for NDT’s requirements whenever is required site weld;
 Ensure and interpret the NDT’s reports in order to assure right interpretation whenever is
applicable;
 Take corrective actions to production department if any deviations from the technical
specifications;
 Raise Non-Conformance Records, and ensure appropriate corrective action and close out;
 Coordination with project subcontractors in order to assure the quality requirements as per project
technical specifications;
 Compliance as per approved ITP with respect to project specifications.
Safety Officer
 Generate and conduct daily TBT prior start of work in coordination with site superintendent;
 Coordinate with site erection in-charge and site engineer/superintendent for HSE requirements and
necessary work permits at the site, Prior to start of erection activities;
 Responsible for monitoring and assessing hazardous and unsafe situations and developing measures to
assure personnel safety;
 To correct unsafe acts or conditions through the regular line of authority, although the HSE Officer may
exercise emergency authority to prevent or stop unsafe acts when immediate action is required;
 Ensure the site Safety and Health plan is prepared and implemented;
 Responsible to investigate all accidents and Incidents. if any, document the same with proper related
reports and necessary action Plan;
 Establish and maintain an up-to-date library on relevant publications, legal regulations and instruction
concerning Safety Standards. Ensure company safety policy statement is displayed and all employees
are aware of the same;
 Conduct safety induction training to all employees;
 Promote and comply to all HSE requirements at all times, through the safety management system
procedures and enhance continual improvement;
 Generate Check list for all lifting equipment’s; like mobile cranes, man lifts, chain pullers, lever blocks,
lifting belts, lifting chains etc. and monitor on daily basis or whenever is required to ensure they are in
Safe functional condition;
 Temporary scaffolding should be monitored daily or whenever is required. Verify the tag certificates
validity and ensure it’s done through certified scolders and checked by certified scaffolding foreman
prior to any erection;

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 Daily monitoring and implementing the PPE requirements to all staff and workers reported to the site:
Safety shoes, safety helmets, adequate coveralls, safety glass, hand gloves etc. special attention
should be taken for the employees working at heights, and should wear safety harness to prevent
potential fall.
1.1 Location of Works

 KAMOA, MSS shop fabrication;
1.4 Referenced Documents
 Contract specification;
 Material Submittal;
 Occupation, Health, Safety and Environment Management;
 Project Quality Plan;
 Method Statement for Steel Structure Fabrication;
 ITP for Steel Structure fabrication;
Health, Safety and Environment

2.1 Health and Safety
Safety & Housekeeping
 Safety is as important as production, quality and cost control and is an essential partner to safe and
efficient operation. Housekeeping shall be carried out in a regular basis.
General
 Since erection of structural steel is carried out at heights, every person engaged in this work should
make every effort to prevent any accident, flying of materials, Fire and Explosion.
Safety Gadget Person
 All workers to wear their own PPE while working on the job site;
 All people working at elevated place, should tighten their own safety harness and the rope shall be
hooked to the nearest secured fixed support, which is higher than the working platform;
 Man lift to be used for tightening of bolts, as well as welding work if any;
 Safety Net shall be installed at the lower portion of steel truss member, if required;
 Dangerous work such as lifting, installing and removing scaffolding shall be isolated by demarking the
area with barricade tape;
Counter Measure against the Strong Wind

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 The lifting work should be suspended when the strong wind is blowing over 32 Km/Hrs (20 Mph) and
scaffolding installed at the high place above the ground should be fastens strictly with nearest
structural for safety;
 All cranes shall have to be sheltered and anchored on boom down with its turntable on lock-mode
during strong wind;
 Mobile cranes, articulated and scissor lifts should be brought down.
Tool Box Meeting
 Regularly all workers should attend consolidated morning meeting and after finish, they attend group
wise separate toolbox meetings, if in case misunderstandings;
 At the tool box meeting, they shall discuss safe work practices, general awareness, work schedule, work
procedure, etc.
2.2 Environment
Aspects:
 Use of plant machinery and equipment.
Impact:
 Potential source of dust that will affect taxiway, establishments and buildings in the vicinity;
 Contamination of soil from equipment;
 Air pollution (crane or trucks exhaust emissions).
Mitigating Measures:
 All the equipment & tools used for the work should be in good working condition, properly maintained
and certified by the 3rd party;
 No equipment emitting excessive black smoke shall be permitted to operate on the construction site.
Regular plant and equipment inspections shall also monitor;
 Oils will be sampled at the earliest opportunity and drained and disposed of through a licensed
undertaker;
 All environment issues shall be reported to the engineer and the safety department for further
investigation;
 Tool boxes talks shall be given regularly to reiterate the environmental hazards of an existing work
activity or to high light the risks of a new activity. All briefings and tool box talks are to be conducted.
3 Materials, Equipment and Manpower
Materials:
 Safety equipment (PPE, safety cones, mesh and barriers, warning tapes);
 Steel structures.

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4 Quality Assurance and Quality Control Measures

 To allow the Consultant to inspect the Works, the Contractor shall give the Consultant a minimum of
24 hours’ notice of carrying out the following activities on site;
 All Laying of steel structures elements, shall store in dry conditions;
For levels and elevations controlling, surveyor team will be deployed to site for horizontal and vertical
alignments;
 QC Inspector will independently carry out surveillance of the works using approved ITP;
 Approved ITP should be implemented following approved erection drawings.
5. Sequence of Works
 Drawing and document;
 Material procurement;
 Receiving materials;
 Material storage;
 Tools, equipment & machines;
 Marking;
 Cutting cleaning and surface preparation;
 Drilling/machining and surface preparation;
 Surface finish;
 Non-destructive examination;
 Correction of strain/straightening;
 Final inspection and release for galvanizing &painting;
 Surface preparation and galvanizing;
 Surface preparation and painting;
 Transportation.
5.1. Fabrication Process

5.2. Drawing & Document
 The design drawings and documents calculations are provided by “as per Contract”;
 Shop and erection drawings to be provided by “as per Contract”.
5.3 Material Procurement
 Raw materials to be procured by “as per Contract”, in line with the project specification.
 Materials to be supplied by “as per Contract” in accordance with the design specifications and project
requirements.
5.4 Receiving Materials

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 Upon delivery of bulk materials, the material shall be inspected for shape, dimension, and
confirmation of quality and appearance by cross-checking against the order list;
 If the inspection cannot be conducted upon delivery, the inspection shall be conducted at the earliest
possible;
 Receiving inspection shall be recorded in form “Material Inspection Report”.
5.5 Material Storage
 All material shall be separately stored according to shape dimensions, grade and class;
 Materials to be stored shall be protected by wood slipper to prevent material’s pre and post
fabrication and welding distortions / sagging;
 The storage shall be in such ways, to enable easy identify of material tractability / identification no
like: HT no, marks no, item no. etc.
5.6 Tools, Equipment & Machineries
 All measuring equipment used during fabrication and erection should be calibrated and recorded in
master list to enable easy traceability and equipment status;
 All Lifting Tools/Equipment and Lifting Machineries should be calibrated and recorded (Third Party
Inspection);
 Machineries like (CNCs, manual or semiautomatic gas cutting machine, saw cutting machine, shearing
machine, etc.) is well maintained and corroborated with a preventive maintenance plan.
5.7 Marking
 Straightening of plates and structural steel shall be properly performed prior to lay-out;
 Marking-off works shall be prepared properly in consideration of acceptance Criteria, welding strain,
shrinkage and materials, for all markings which involving more than two dimensions;
 Part or assembled items can be marked manually or automatic in CNC system.
5.8 Cutting, Cleaning & Surface Preparation
 Ensure the dimensions of the plate is maintained as per drawings;
 Ensure the flatness of the plate is within acceptances criteria;
 Due to flame cutting system undercuts might occur. As rectification, local buildup touchup and flush
grinding shall be applied;
 Fit-up will carried out as per drawings;
 Maintain proper connection between base plates and roof steel frame elements;
 Ensure the fillet weld joint is achieved as per IFC drawings;
 Welding shrinkage, deformation and finishing allowance shall be considered for cutting;
 Cutting works by means of shearing, sawing, gas cutting, etc., shall be performed using mechanical
guided tool as much as possible. During cutting all necessary safety precaution to be applied;
 Sharp edges of all materials, shall be rounded and made smooth;

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 Generally, all bracings and its attachments shall be cold cutting by bend saw cutting machine and or
hot cutting by CNC flame / plasma cutting machine;
 All welded joints should be ground smooth / cleaned / de burring / free of spatter.
5.9 Drilling / Machining & Surface Preparation
 For bolted connections of steel structures, gusset plates, base plates, etc. holes are drilled by either
cold drilling or punching;
 Cold drilling method shall be used for thickness above 16 mm, and in case of wall thickness less
than 16mm punching method can be applied;
 All holes shall be at right angle to each surface of the materials with the exception of those
particularly specified in the drawings;
 Any defects such as burrs, turn strain etc. around the holes shall be removed.
5.10 Fabrication / Fit up
 Proper measuring tapes, tools shall be used during fit-up works;
 Tolerance for the fabrication of the steel structure shall be maintained as specified on the applicable
fabrication drawing and or inspection procedure document stipulated in the data sheet and control
drawing – reference code: SANS 2001-CS1
 Fit-up with temporary support is acceptable if required, but all supports should be properly removed
after full welding;
 Fit up must be inspected by QC prior to welding;
 Fabrication sequences for main structural components:
 Roof steel structure and its accessories;
 For quality and mismatching assurance trial assembly is recommended prior site delivery;
 QC inspection report will be performed and recorded as per approved ITP / check list.
5.11 Workshop Welding Works
 All welding should be carried out as per approved Drawings and WPS;
 Welding rods / filler wires shall be used for welding should be heated to desire temperature as
recommended by the manufacturer prior to use;
 Suitable measures shall be taken to reduce deformations and shrinkage by welding;
 In windy places, welding shall be performed under condition of shielding wind.
 Special care should be administered in case of wind, during flux cored arc welding (FCAW). And
welding should be stopped in case of wind speed more than 2 meters per second.
 After welding proper treatment shall be performed to welded surfaces and any defects such as over
lapping, unevenness of bead, undercut, pits, slug’s inclusion, crater, lack of welding etc. shall be
rectified. When a crack is detected on the weld metal, the defective surface on the weld metal shall
be eliminate of all the length of welding line and its portion shall be gouged out and shall be re-
welded.

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5.12 Surface Finish

 Weld spatter, arc strike, fluxes and sharp edges shall be removed by grinding during the finishing works.
5.13 Non-Destructive Examination (NDE)
 NDE are performed by certified third party / QAQC Dept. as per approved ITP.
5.14 Correction of Strain / Straightening
 Any strain caused during fabrication works, especially by welding shall be corrected by means of
mechanical method so as not to damage the surface of materials. Press machine and bending machine
can be applied;
 Hot straightening shall be avoided.
5.15 Final Inspection & Release for Painting
 All inspections should be done as per approved ITP;
 Final Inspection shall be conducted after completion of the fabrication process prior to releasing the
items for Galvanizing / Painting;
 The inspection will be conducted by QC;
 As per approved ITP, main Contractor QC representatives should ensure required intervention check.
5.16 Surface preparation & Galvanizing
 Surface Preparation and galvanizing of steel structure will be carried out by an external / internal service
provider;
 Galvanizing system will be followed, as per the project specification and approved ITP.
5.17 Surface Preparation & Painting
 Surface Preparation and Painting of steel structure, shall be carried out by the paint applicator;
 Painting Schedule or Coating system will be followed as per approved ITP.
5.18 Transportation
 Proper transport shall be used for shifting the steel structure components from Shop to the required
sites;
 During transportation wood pieces shall be used between steel structure components to prevent
friction and paint damage;
 Special transporting permit shall be obtained, if in case the transporting load exceeds the allowable
transporting limits w.r.t height, width and length.
5.19 Workshop Material Handling & Storage
 Certified lifting belts, shackles, chains and slings shall be used in the handling process;
 Materials are stored in such a way to ensure; material identification is visible and readable for
traceability;
 On receipt the raw materials shall be carefully unloaded and examined for defects, checked and sorted
according to its erection sequence requirements. The steels must be supported with wooden skids
above clean and dry ground;

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 Trusses / Rafter and other members after fabrication, shall be supported properly to avoid potential
deflections;
 All steel structure members shall be stored and handed in such a manner, that it is not subjected to
excessive stress, which may cause damaged;
 Bolts shall be stored in dry and clean containers covered with water proofed sheets. Packages of bolts
shall be opened shortly before it will use;
 Any materials found damaged or defective shall be quarantined separately and the damaged or
defective portions shall be identified by paint applied in distinct color.
6.0. INSTALLATION OF STEEL STRUCTURE

6.1. Erection Process
6.1.1. General Requirements
 Safety of workers is always the priority throughout the execution of the work.
 The work shall be performed in accordance with this document, structural drawings, plot plan and other
documents prepared and approved by the consultant.
 All Structural members delivered shall be stored in the designated storage area, near the erection area.
 Hoist and transport of the equipment shall be carried out by the skilled workers having sufficient
experience, rigging and rope – knotting work in compliance with safety regulations.
 Necessary permission to use fire shall be obtained prior to the use of fire and the responsible supervisor
shall attend throughout the completion of the work.
 No welding, gas cutting and other similar activities will be accepted in area designated for painted steel
structure.
 If, in case of rework, the structural component subjected for rework shall be removed and shifted to the
designated area for fireworks; the activity shall be supervised by a fire man and the area should have
sufficient quantities of fire extinguishers.
 Only experienced and certified welders shall carry out welding works.
 Adequate scaffolding and man lifts must be provided for workmen to reach all parts of the work safely.
 All scaffolds, temporary access and ladders shall be inspected by the Safety Officer prior to its use.
 All tools and equipment must be kept in safe working condition and shall be inspected regularly.
6.1.2. Site Material Handling & Storage
 Certified lifting belts, shackles, chains and slings will be used in handling process.
 Materials are stored in way, in which, its identification is visible and readable for easy access and
materials traceability.
 After receiving the material at Site, the fabricated materials shall be carefully unloaded and examined for
defects, checked and sorted according to its erection sequence requirements. The steels must be

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supported with wooden skids above clean and dry ground. Trusses / Rafter and other members, shall be
supported properly to avoid unnecessary deflection.
 The steel structure members shall be stored and handed in such a manner that none of the members are
subjected to stress, which may cause damaged.
 Bolts shall be stored in dry and clean containers covered with water proofed sheets. Packages of bolts
shall be opened shortly before it will use.
 The fabricated material shall be verified with respect to markings on the match marking drawings and
shipping list supplied. Any materials found damaged or defective shall be stacked separately and the
damage or defective portions shall be identified by paint applied in distinct color .
6.1.3. Re-Survey
 Prior to start the erection work, re-survey shall be conducted in the presence of the Contractor’s site
dimension surveyor and anchor erector to determine the accuracy of grid lines dimensions, anchor bolts
distance and plumpness, level and elevations.
 Site surveyor will be provided by main contractor.
 Non-compliance shall be corrected prior to erection works.
 All reference and control points shall be fixed near the work site for facilitating the erection work.
 All anchors bolt and base plate’s coordinates are generated and confirmed by contractor .
6.1.4. Hoisting Steps & Lifting Plan
Hoisting operation shall be carried out in accordance with the following procedure:
 Positioning of lifting equipment, base conditions under out – rigger, operation circle, etc. shall carefully
be examined before the work.
 Before winding up, check all the condition, such as crane positioning, wire arrangement, etc.
 Wind up a little to check the loading conditions. Check the whole situation carefully.
 If any dangerous and / or abnormal condition is observed, immediately pull down the member
 Make necessary reinforcement or suitable safe arrangement.
 Proceed with the wind-up and transfer operation slowly and carefully.
 Hoisting work shall not be interrupted under any dangerous situation. (Example: Interruption during
hanging situation).
 Hoisting or pulling down shall be directed by single responsible supervisor. Whistle and hand signal shall
be used in regular method. Further, a line – system to transmit the instruction thoroughly form the top to
bottom level workers shall be organized.
 Erection shall not be executed on rainy days, in strong windy, sandstorm, and after sunset without
adequate lighting.
 Erection sequence shall be followed as per the client priority and project specification.

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 Certified rigging staff to be provided in coordination with main contractor.

6.1.5. Sequence
 Embedded base plates;
 Inclined bracings;
 Roof trusses elements;
 Roof bracings elements;
 Facade steel structural frame.
The above erection details and sequence are provided to ensure the structural stability, alignment of the
columns and beams while erection process. All the Steel structural installation should be carried out as
per the approved erection drawing.
6.1.6. Bolting
 Field bolt connections shall be accurately fitted before the bolts are inserted. The number of bolts for
temporary setting shall be more than 1/3 of the specified number of bolts of each part. Finished bolts
shall not be used for temporary bolting.
 Permanent bolts tightening torques value should be maintained.
 For bolts tightening shall use standard calibrated torque.
 During the bolting scaffolds or articulated man lift will be used.
 Calibration of articulated man lift and service certificate should be available during erection.
 Qualified and trained operator will be used to operate the articulated man lift.
 Bolts tightening should be provided as per approved torques values reflected in the erection drawings.
6.1.7. Site Welding
 Site welding generally is not applicable except extreme situation.
 Wherever required site welding should be in accordance with AWS D1.1 standard.
 All sites welding shall be performed in accordance with requirement for the shop welding, except for
such requirement which applies specifically to shop condition only.
 Where steel has been delivered painted, before the field welding, the paint shall be removed at least
50mm on both sides of the joints.
 All post weld spatters should be removed;
 Welding irregularities and undercuts are not accepted.
All bevels and joints should be verified and released for welding after QC inspector inspections and
reports.
 All field welding reworks should be under the direct supervision of welding supervisor / foremen
corroborated by specialist if need.
 In case of site welding required – area to be barricaded area and ensure necessary fire extinguishers &
fire proofed tarpaulin for welding activity.

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 Welder will wear all safety PPE (apron, leather gloves …etc.)
 Underneath of the welding material cover with fire blanket.
 Depute fire watchman during the welding operation.
6.1.8. Hot Work
 Prior start any Hot works where is involving open fire, proper inspection and clearance, work permit
should be provided by safety officer.
 Grinding, cutting and welding process are considered as hot work process.
 All hot work process will be done in barricaded area.
 Proper grinding and cutting tools will be maintained in the maintenance report.
 All machine service report will be given upon on request.
 All consumable will be kept in the separate container.
 Machine will be checked periodically by the maintenance team.
 All Electrical wire and cable will be check by electrician.
 Color code of each item will be checked and marked.
 Prior to start the work, work permit should be obtained by site superintendent.
 The hot work area should be supervised continuously during the activity by the supervisor /foremen.
 Fire extinguisher should be kept where the hot work is carried out.
 Inspection to be carried out after hot work.
6.1.9. Working at Height
 All workers shall be protected from falls of 1.2 meter or more by the use of an approved fall protection
system.
 Roof edge barriers (or scaffolds) must be erected to prevent people and materials falling.
 Calibrated Safety harness will be used for working at height.
 Calibrated certificate of safety harness will be given upon request.
 All harness should by check and monitored by the foreman.
 Damaged harness will be considering as not useable and marked as RED.
 When working at height –Life line will be made and checked with safety team.
 Once the worker reached the life line, he will hook himself to it.
 All working at heights is supervised by Safety Officer.
 Tool box meeting to be carried out before start the work.
6.1.10. Use of Mobile Elevated Work Platforms
 For bolting purpose of beams, will use articulated man lift or proper scaffolding.
 Scaffolding will be inspected by the Safety Officer and will be accordingly TAGGED.
 Only qualified articulated man lift operator will allowed to operate the machine.
 All articulated man lift moving will be controlled by flagman.

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 Articulated man lift will be serviced periodically.

 Service and maintenance report of articulated man lift will be given upon request.
 Maximum height of 22meter long articulated man lift will be used.
6.1.11. Painting (Touch up)
 Immediately after the inspection of the field welding, the connecting joint shall be painted with paint
specified for the project. Scratches or damage paint during handling and lifting shall rectify.
6.1.12. Grouting
 Grouting shall be carried out only after a sufficient portion of the steel works including columns, trusses,
bracing, etc. has been properly aligned, leveled and plumbed.
 Immediately before grouting, the space under the plate and around the bolts shall be thoroughly cleaned
and free from any foreign matters. These activities shall be performed by contractor.
 Only approved grouting material shall be used at site.
6.1.13. Safety & Housekeeping
 Safety is as important as production, quality and cost control and is an essential partner to safe and
efficient operation.
 Housekeeping shall be carried out in a regular basis.
6.1.13.1. General
 Since erection of structural steel is carried out at high place above the ground, every person engages in
this work should make every effort to prevent an accident from falling / flying materials / fire and
explosion.
6.1.13.2. Safety Gadget Person
 All workers to wear their own PPE while working on the job site;
 All people working at elevated place, should tighten their own safety harness and the rope shall be
hooked to the nearest secured fixed support, which is higher than the working platform;
 Man lift to be used for tightening of bolts, as well as welding work if any;
 Safety Net shall be installed at the lower portion of steel truss member, if required;
 Dangerous work such as lifting, installing and removing scaffolding shall be isolated by demarking
the area with barricade tape;
 Third party not concerned with the work shall not be allowed to come into the working area.
6.1.13.3. Counter Measure against the Strong Wind
 The lifting work should be suspended when the strong wind is blowing over 16m/s and scaffolding
installed at the high place above the ground should be fastens strictly with nearest structural for safety;
 All cranes shall have to be sheltered and anchored on boom down with its turntable on lock-mode during

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strong wind;
 Mobile cranes, articulated and scissor lifts should be brought down.
 In case of heavy wind, rain, fire and other calamities, emergency access ways should be identified and
provided and visible marked by main contractor safety departments for emergency exit of erection team.
6.1.13.4. Erection Execution Process
As per the Erection Drawing No# and the safety regulation will be followed and monitored.
6.1.13.5. Tool Box Meeting
 Regularly all workers should attend consolidated morning meeting, and after finish, they attend group
wise separate toolbox meetings, if in case misunderstandings;
 At the tool box meeting, they shall discuss safe work practices, general awareness, work schedule,
work procedure, etc.
Records :
ITP Reference No :

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METHOD STATEMENT
FOR
WATERPROOFING WORK

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WATERPROOFING WORK
General:
Raw Materials used in Waterproofing & its Acceptance Criteria
Cement:
Cement shall be 43 / 53 grade OPC (Fly ash shall be used with OPC) / PPC and not more than 8 weeks old
and it shall be free of lumps.
Natural sand:
Silt content of natural sand shall not exceed 12% by volume for 1 Hr and 8% by volume for 2Hrs.
Percentage passing 600 microns shall be more than 45%.
Fly ash:
1) Sources of fly ash must be standardized as per test reports and fly ash must meet the requirements of
IS 3812. Further retention on 45-micron sieve after wet sieving should be less than 20%.
2) Fly ash should be free from lumps.
Bricks:
Bricks from which brick-bats are made shall not be under burnt and percentage of over burnt bricks shall
not be greater than 10%. Bricks used for brick bats shall be either be full bricks or 3/4th bricks. Bricks
shall be broken at site with the help of mallet. Irregular broken pieces of bricks shall not be used.
Water:
Sulphate and Chlorides content in the water shall be within specified limits as specified in IS-456:2000.
Water proofing compound:
A water proofing compound of reputed manufacturer shall be used. Care shall be taken to see that it is
compatible with the type / brand of cement being used. Packing shall clearly bear date of
manufacturing, lot number, date of expiry, usage guidelines etc.
Glazed tile pieces (for China Mosaic Type Waterproofing):
Broken pieces of selected white / coloured glazed tile pieces of size 25mm to 50mm and 6mm thick or as
specified on drawing.
Bonding Agent:
Suitable bonding agent from the reputed manufacturer shall be used.
Rough Shahabad stones or equivalent stones from quarry:
Rough Shahabad Stone slabs shall be of uniform size and shall be free from cracks and fissures.

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Basic Types of waterproofing

 Waterproofing of Toilets
 Waterproofing of Terraces
 Box type waterproofing for underground tanks
 Procedures for Waterproofing of Toilets:
Pre-Waterproofing Procedures:
1) It shall be ensured that toilet plumbing lines are installed in masonry and chases are rendered with
non-shrink grout prior to cleaning activity of sunk is undertaken.
2) Cleaning of sunk slab base and sides of beams shall be carried out as regards all those materials,
mortar, oil, grease etc. thoroughly by wire brush and the area shall be washed clean and surface should
be wet.
3) Injection grouting at all major honeycombed portions shall be carried out, if necessary, after physical
observation of the sunk.
4) Sunk slab shall be cured for at least 2 days by ponding, to test for leakages and to serve water hungry
concrete surface.
5) In case of major leakage, gravity grouting or pressure grouting shall be resorted to, to stop leakages.
6) Holes for PVC and other outlet pipes shall be marked clearly for size and locations. Outer surface of
PVC pipes shall be roughened for better bonding. Diameter of hole shall not exceed pipe diameter.
7) Levels of water-proofing shall be clearly marked on the toilet walls with slope towards outlet, as
specified in drawing or minimum 1:100 otherwise.
During Waterproofing Procedures:
1) Application of chemical waterproofing coat (crystalline / elastomeric / polymer) can be done, if
required to entire sunk portion before base coat.
2) Base coat using cement mortar in proportion 1:4 or as specified by QA Department with approved
waterproofing compound shall be applied over top of base slab of sunk. Maximum thickness of base
coat shall be 25 mm at upper end of slope.
3) Proper slope shall be given to base coat as per drawing towards drain spout and drain spout to be
fitted simultaneously with the base coat, as an additional precaution to take care of seepage, if any.
Base coat shall also be applied to the sides of the toilet sunk up to one foot above the finished floor level
(F.F.L) of the adjacent floor.
3) Drain spout shall be 20 mm / 25mm diameter GI / UPVC, fixed so as to project at least 4” beyond wall
surface. Drain spout mouth shall be cut to the shape of half nozzle by cutting at 30º angle to facilitate
water dropping in the form of a projectile. Holes for drain pipes should be done before starting any type
of waterproofing.
4) Drain pipe mouth shall be fitted with PVC grating or filter media form inside and chicken mesh / wire
mesh

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from outside.
5) Curing of base coat shall be done by ponding for 3 days and checked against leakage. Leakage, if
observed, shall be rendered with reapplication of base coat to ensure no leakage.
6) Floor traps and other plumbing lines shall be installed in brick masonry after application of base coat.
7) Slope of 1:100 shall be provided for toilet piping and water proofing. Floor trap shall be fixed with
respect to finished floor level (F.F.L) of the toilet.
8) Rendering of holes shall be done using compatible bonding agents; SBR based expansive grouts,
waterproofing compounds and M15 grade concrete.
9) All internal drain lines shall be erected as per layout given on the drawing and shall be pressure
tested.
10) Application of brick bat coba shall be started, once plumbing lines are satisfactory pressure tested.
11) Bricks selected for using as Brick Bat Coba shall be either full brick or 3/4th brick made out of one
complete brick by breaking into required size, using mallets.
12) Brick bat shall not be stored in the form of a heap at one place and soaked thoroughly for about 15
minutes prior to their placing.
13) Use of plasticizer in mortars is recommended to increase workability. Mortar mixed shall be used
within 1 Hour of preparation.
14) Pre-soaked brick-bats shall then be laid in straight / radial, by inserting brickbats to a depth of about
15mm by light tamping with the help of mallets. Thickness between adjacent layers of brickbats shall
not exceed 25mm.
15) Application of brick-bats shall proceed from one corner and shall be laid in radial pattern / straight
pattern to drain of any water which has seeped through. Thiyya (level pads)s (level pads) for the same
shall be given by Site Engineer, considering into account adequate slope.
16) Edge rounding shall be done simultaneously at corners. (Junction of slab & wall)
17) The brickbat Layer shall then be cured for minimum 3 days by ponding
18) After curing is over, the surface shall be applied with a finishing coat of cement sand mortar in the
proportion 1:3 with water-proofing compound till top of brick-bats.
19) Top coat shall be of neat cement slurry of adequate consistency and shall be monolithic with brick-
bats.
20) Finished surface shall then be cured for at least 7 days by ponding and then tested for leakages, if
any.
Post Waterproofing Procedures:
Date of finishing shall be marked on the surface for curing by ponding for about 7 days.
NOTES:

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 Water-proofing once done, shall not be broken or pierced. If water proofing is to be punctured, due
care shall be taken to limit the damage to the restricted area. The cracks due to hammering shall not
spread over the large area.
 Repairing of the punctured area shall be done by using bonding agent and expansive grouts.
For precise waterproofing works, the following procedure can also be used depending upon the
requirement of the project.
First Coat (Base Coat) of Water Proofing:
1) Over RCC surface, crystalline waterproofing or chemical treatment must be required to apply. Apply
this coat on floor and walls about 1’ above finished floor level (F.F.L) and also outside toilet door outer
frame face of entrance of toilet.
OR
1) Apply waterproofing coat with admixture and cement in the ratio as specified by manufacturer by
weight applied on R.C.C surface in two coats, duration between first and second coat shall be min 4 hrs
and max 24 hrs.
2) First coat chat of 1:4 waterproofing plaster with waterproofing admixture to be applied over the
above coat.
3) Second coat of water proofing “seal roof” shall be layer of plaster 15 mm thick in which metal of 15 to
20 mm nominal size will be embedded / fixed by hand at random with mortar mixed in proportion 1: 3.
Aggregate use for waterproofing should be as per IS: 383
4) Above treatment shall be then cured for at least 24 Hours.
5) Provide water escape pipe 25 mm dia (1”) G.I. / U.P.V.C. pipe just above the base coat with filter
media fixed from inside. (Holes of such pipes should be made prior to the base coat).
6) Over the base coat, plumber shall be instructed to fit P-traps in the required level along with U.P.V.C /
C.I. outlet pipe.
7) Third coat of water proofing shall be applied with a layer of “seal roof” plaster of about 10 to 15mm
above the stone aggregate. The treatment shall be carried out on side of sunken slab and side walls up
to 2’ above finished floor level (F.F.L). The thickness of the treatment on the wall will be about 20 mm
and the mix should be of proportion 1:4.
8) The above treatment shall be cured for at least 24 hours.
9) Elastomeric / polymer coating must be required to apply on above treatment.
10) After completion of above treatment, the plumber shall finish all his plumbing work without
breaking or disturbing water proofing treatment.
Brick Bat Coba Water Proofing:
1) Select well burnt brick bats. Use of over burnt brick bats should be strictly avoided.
2) Before laying brick bats, it should be soaked thoroughly in water, for at least half an hour and then lay
the brick bat on the edge (kodi) and not on a flat surface.

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3) Now fill the depression sunken portion with brick bats coba method with bricks laid on the edge and
not on flat surface up to required level with maintaining slope 1:60 or 80
4) Any gaps between the brick bats should be filled with mortar. Complete the brickbat coba coat with
joints filled with cement mortar 1:5 proportions. Also use water-proofing compound as per the specified
dose per bag of cement, while filling the joint.
5) The treatment shall then be cure for at least 24 hours.
6) All the holes made in the wall for P.V.C. / C.I. pipe connections should be finished with water-proofing
coba along with this coat.
7) Cure this coat by ponding water for four days and check for any leakages.
Final Coat of Water Proofing:
1) Final coat of water proofing shall now provide about 12 mm above the brick bats layer which should
be rough finished with a wire brush, for bonding of the horizontal filler coat. The final coat will have
proper slope 1:60 or 80 towards floor trap.
2) Continue this coat on the side walls, up to 45 cms (18”) above W.C. floor level. This coat should not
project out beyond the plastering coat of the W.C. walls, so as to avoid unnecessary thickness of the
glazed tile dado.
3) At the entrance door of toilet, floor level of toilet should be at least 10 mm drop with respect to
finished floor level of adjacent room or passage.
4) This final coat shall be cured for a minimum of seven days, with water up to minimum 7.5 cm depth.
5) Toilet tile joints should be filled only by using tile grout-SBR base.
Acceptance of completed works:
Type of check Acceptance
Leakage during ponding of base coat Not accepted
Leakage during ponding of Brick-bat coba Not accepted
Slope given to for neat cement over Brick-bat As per recommendation
coba
 Procedures for waterproofing of Common / Open Terrace (Brick Bat Coba / Mosaic finish):
1) All surfaces to be waterproofed shall be cleaned off all loose materials, mortar, oil, grease, if any,
thoroughly by wire brush. It shall be ensured that parapet plasters are completed prior to cleaning
activity is undertaken. Plaster shall be cut at one level, i.e. 1’ above terrace slab top.
2) Injection grouting shall be adopted at all major honeycombed portions, if necessary, after physical
observation of slab.
3) Terrace slab shall be cured for at least 2 days by ponding to test for leakages and to serve water
hungry concrete surface.

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4) Ponding shall be done in areas of 5 m 2 each by forming bunds of 2” in height and cast in cement
mortar 1:10.
5) In case of major leakages, gravity grouting or pressure grouting shall be resorted to, to stop leakage.
6) Levels of water-proofing shall be clearly mark on concrete surface, clearly defining ridge line and
valley lines with level pads underneath, minimum slope being 1:100 or as that mentioned in drawing.
7) Holes for outlet pipes shall be marked clearly for size & locations and chasing shall be done thereafter.
Hole diameter shall not exceed pipe diameter. Rendering of holes shall be executed using compatible
bonding agents, (SBR based) expansive grouts, waterproofing compound and M15 grade concrete.
8) Rainwater pipes shall be fixed at the required locations as per drawing. In case of PVC pipes, surface
of pipes shall be roughened and applied with sand for proper bonding and PVC grating shall be provided
at the pipe mouths.
9) It shall be ensured that no water carrying pipes are running over the slab, which is to be water-
proofed.
10) Materials required for only 2 days of water-proofing works shall be carried to avoid unnecessary
loading of terrace slab.
1) Bricks selected for using as Brick Bat Coba shall be either full brick, or 3/4th brick made out of one
complete brick by breaking into required size, using mallets.
2) Brick bat shall not be stored in the form of a heap at one place.
3) They shall be soaked thoroughly for about 15 minutes prior to their placing.
4) Glazed tile pieces for China Mosaic Type Water-proofing shall be soaked for about 15 minutes before
fixing.
5) After cleaning the slab, a thin layer of cement slurry shall be laid on cleaned slab prior to laying of
brick bats.
6) Over this, maximum 40 mm thick layer of cement sand mortar in the proportion 1:3 mixed with
compatible waterproofing compound shall be laid.
7) Mortar shall be preferable mixed in mechanical mixer only. Also, use of plasticizer is recommended to
increase workability. Mortar prepared shall be used within 1 Hour of preparation.
8) Pre-soaked brick-bats shall then be laid in radial, by inserting brick-bats to a depth of about 15mm by
light tamping with the help of adjacent layers of brickbats shall not exceed 25mm.
9) Application of brickbats shall proceed from one corner and shall be laid in radial pattern to drain of
any water which has seeped through. Thiyya (level pads) s for the same shall be given by Site Engineer,
considering into account adequate slope. For this purpose, line dories shall be fixed at every 3’ to define
the slope. Brick-bats shall be laid accordingly.
10) Edge rounding shall be done simultaneously so that bottom edge of parapet wall plaster serves as
drip mould (Kani).

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11) The entire brick bat layer should be cured of minimum 3 days.
11) After curing is over, the surface shall be applied with a finishing coat of cement sand mortar in the
proportion 1:3 with water-proofing compound.
12) Top coat shall be of neat cement slurry of adequate consistency and shall be monolithic with brick-
bats. Surface shall be finished with 3’ long float, polish patra and line dori to mark grids of 1 X 1 sq. ft.
markings.
13) Finished surface is then tested for leakage by ponding. Ponding is done making mortar bunds of
height 1” at every 5 feet. Testing shall be carried out for 7 days.
For China Mosaic Type water-proofing, following procedure shall be adopted:
1) After curing of finishing coat (which is roughened) a layer of cement sand mortar 1:3 in proportion
and 20mm thick mixed with approved water proofing compound shall be laid over it.
2) While the bed mortar is fresh, white/coloured glass pieces shall be set closely by hand with glazed
side keeping exposed.
3) Wooden mallets shall be used for tamping China Mosaic tile pieces into place.
4) Ponding (Wattas) shall be made with mortar bedding with glazed tile pieces on top.
5) Surface of tiles shall be lightly rolled with wooden roller taking care that no hollow pockets are left
underneath glazed tile pieces.
6) Top surface shall be cleaned with saw dust or cotton waste and if necessary, with weak acid solution
to remove stains of cement. Due care is taken to see to it that cement in the joints does not dissolve in
the acid solution.
7) Slope of finished top shall be 1:100 or as mentioned on the drawing.
8) Finished surface shall be cured for at least 7 days by flooding and checked for leakages/dampness, if
any.
Date of finishing shall be marked on the surface for curing by ponding for about 7 days.
NOTES:
 Waterproofing once done, shall not be broken, or pierced. If waterproofing is to be punctured, due
care shall be taken to limit the damage to the restricted area. The cracks due to hammering shall not
spread over the large area.
 Repairing of the punctured area shall be done by using bonding agent and expansive grout.
Acceptance of Completed work
Open Terrace :( Brick-Bat Coba )

Entire terrace to be flooded with water for 7 days No leakage should be observed from underneath.

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after top coat application, blocking all rainwater

pipes.
After the test is over, temporary blockages of rain Water should be drained off completely
water pipes are removed. without any stagnation
Slope given to waterproofed area As per drawing
Rain water pipes Projecting ½” inside terrace and provided with
grating. Hole rendered with non-shrink grout.
Rounding at edges of parapet Merged inside wall plaster on parapet wall
Final coat of neat cement Smooth finish
Common Terrace: ( China Mosaic )
Undulations on finished surface Shall not be observed
Leakages/Damp spots after ponding Shall not be observed
Water stagnation Shall not be observed
Rain water outlets Shall be blocked in final coat
 Procedures for Box-type Water-proofing for Underground Water Tanks:
1) Ground shall be excavated at least 750 mm beyond the external faces of the walls of RCC tanks, the
additional excavated space acting as working space.
2) If water table already exists within the excavated area, then the excavated area shall be kept
sufficiently dry by creating a bund all rounds.
3) Bund shall be created with the help of sand bags filled with puddle and gaps between sand bags being
filed with puddle.
4) The area shall then be dewatered using a dewatering pump of suitable capacity ranging from 2 Hp to
5 Hp depending upon amount of water to be removed.
5) Shahabad stones received on site shall be cut and dressed to correct sizes as required.
6) Shahabad stones shall be soaked for 2 Hours before fixing.
1) It shall be ensured that the excavated pit is sufficiently dry before laying PCC and all the raw materials
is made available.
2) PCC proportion as mentioned on drawing shall then be laid on the ground. Thickness of PCC shall be
as per drawing.
3) Care shall be taken so that PCC is laid in perfect level without slope.

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4) PCC extends at least 150 mm beyond the vertical faces of base slab. PCC shall be cured for at least 3
days.
5) Over PCC, 20 mm thick layer of cement sand mortar (1:4) well mixed with water proofing compound
shall be laid over the entire surface of PCC.
6) Proportion of water proofing compound shall be as recommended by the water proofing compound
manufacturer.
7) Mortar shall be preferably mixed in mechanical mixers and unloaded in MS tray and shall be used
within 1 hour of preparation.
8) Next day cement slurry is spread over water proofing layer and Shahabad stones are laid side by side
over it with 10-15 mm gaps between the stone slabs by applying a layer of water proof mortar on backs.
Mortar proportion shall be as mentioned in drawing or as specified by QA Department.
9) Gaps between stone slabs shall be filled with cement sand mortar (1:4) with water proofing
compound or as specified in drawing.
10) Laying of Shahabad stones shall be done over the entire surface of water proofing layer laid earlier.
11) Next day joints between stone slabs shall be raked to a depth of 15 mm and grouted again with the
fresh mortar.
12) Over the stone slabs, 20 mm thick layer of cement sand mortar (1:4) mixed with water proofing
compound shall be laid over the entire surface of stone slabs laid. 12 mm downgraded aggregates shall
be placed at random in this layer.
13) This layer shall be cured for 3 days before starting construction of RCC base slab and walls. RCC base
slab and walls shall be constructed monolithically and as per dimensions mentioned on the drawing.
14) Water proofing layer shall also be applied on top of the projected portion of base slab and cured as
specified.
15) Water proofing of tank walls shall not start unless tank walls are constructed to their full height and
well cured for at least 7 days.
Water Proofing over side walls:
1) A groove of width equal to thickness of Shahabad stones shall be made to the full depth of top water
proofing layer below RCC base slab as also over top of projected portion of base slab.
2) Groove shall be made with the help of round wheel cutter at a distance of 15-20 mm from external
face of base slab, all along the periphery of RCC tank.
3) Within the groove Shahabad stones shall be fixed side by side without leaving any gap between
edges.
4) At a time not more than 3 horizontal layers of stone slabs one above other shall be laid.
5) Gap between vertical slabs being laid and tank walls shall be maintained with the help of suitable
steel spacers, if required, for the purpose of suitability of vertical stone wall being laid.

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6) After the vertical stone wall is erected, the external face of wall shall be applied with 8 mm thick
rough cement sand plaster and cured for 2 days. Enough roughening of this plaster shall be done when
the plaster is green.
7) Gap between stone wall and RCC tank wall shall then be filled with cement sand mortar (1:4) mixed
with /water proofing compound. Care should be taken so that hollow pockets are not formed behind
the vertical stone wall.
8) This sequence of erection of stone wall shall continue till the required height. (Minimum at least 300
mm above ground level)
9) After erection of stone wall, the external rough surface of stone wall shall be applied with finishing
coat of 15 mm thick cement sand mortar (1:4) and cured for 3 days before backfilling starts.
1) Backfilling shall start after satisfactory curing of finishing coat on external water proofing.
2) Backfilling shall be done with murrum or good quality earth in layers of 300 mm thk which are
adequately watered and compacted with rammers.
Acceptance of Completed Work:
Side water proofing provided At least 300 mm above ground level
Base water proofing provided At least 150 mm beyond the external face of RCC
walls
Finished coat over vertical Shahabad tiles In plumb, and corners finished properly
Other Types of waterproofing:
1) Basement Waterproofing
 Bentonite waterproofing system
 Box Type waterproofing system
 Crystallization waterproofing system
 APP Membrane waterproofing: Lift Duct, Sewage Treatment Plant, Swimming Pool, New
construction with tiles, Flower Bed.
2) Terrace Waterproofing: Option 1 / Option 2 / Option 3
3) Podium waterproofing / Kitchen & pantry / toilet – bathroom without sunk / sunk toilets / chajjas /
service area – refuse area / over deck insulation
4) Roof Garden / Podium terrace
 Cementitious membrane waterproofing
 Polyisoprene membrane waterproofing.
 Basement Waterproofing
 Bentonite Waterproofing System Raft Slab / Retaining Wall:

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Providing and laying Voltex / Voltex DS Bentonite Waterproofing System on top of the PCC as per
manufacturer’s specification
Raft Slab:
Providing and installing Voltex / Voltex DS around all foundations (ground beams, pads, pile caps etc.),
Placing Voltex / Voltex DS over the properly prepared substrate with the dark grey (Woven) geotextile
side facing the concrete to be waterproofed (i.e. The white (non-woven) side should face the
groundwater). Overlap all adjoining edges a minimum of 100 mm and stagger ends to minimum of 300
mm. Staple or nail edges together as required to prevent any displacement before and during concrete
placement.
Retaining Wall:
Providing and applying Voltex / Voltex DS by mechanically fastening to cast concrete just prior to
backfilling (post-applied), or by utilizing the peel-adhesion properties of the Voltex / Voltex DS (pre-
applied). The needle punched geotextile fibres, which have been forced from the white (spun) side
through the bentonite and dark grey (woven) side, will be trapped within the wet concrete, and allow
the Voltex DS to remain firmly attached to the concrete after the formwork has been removed.
Bentonite Water Stoppers:
Providing and laying Bentonite waterproofing Stoppers for all construction joints detailing and rock
anchoring if required.
 Box Type Waterproofing System
Providing and laying Box Type waterproofing with single layer rough Shahabad of 25mm thick.
1) Washing the existing concrete surface.
2) Laying 1:3 cement mortar base & laying Shahabad tiles in Cement Mortar 1:3 to required slope as per
drawing. Top coat of 1:3 of cement mortar.
3) Mixing an integral waterproofing compound of approved make at appropriate dosage as
recommended by manufacturer at all stages.
4) Injection grouting with non-shrink cementitious grout of approved manufacturer at construction
joints, and at vulnerable junctions
5) Item shall include curing, cleaning, giving 7 days pond test (for raft) and 10 yrs. guarantee.
Providing and laying Bentonite Water Stoppers for all construction joints detailing and rock anchoring if
required
 Crystallization Waterproofing Systems: Positive Side
Below Basement Raft:
Providing and dry sprinkling on top of PCC prior to pouring of concrete for basement raft, proprietary
“Catalytic” in depth Crystalline waterproofing system as per manufacturer’s specification and as
approved by the engineer-in-charge to permanently fix non soluble crystalline growth throughout the

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capillary tracts and pores of concrete at a speed of minimum 60-65 cms per year inside concrete.
Catalytic in depth crystalline waterproofing system shall be able to withstand at least 460 ft. of water
head pressure. Both the above characteristics shall be supported with an international test report. The
Catalytic in-depth crystalline system or equivalent shall be sprinkled at a minimum coverage rate of 1.2
kg/sqm.
Basement Retaining Wall:
Providing and applying proprietary “Catalytic” in depth Crystalline Waterproofing system as per
manufacturer’s specification and as approved by the engineer-in-charge to permanently fix non soluble
crystalline growth throughout the capillary tracts and pores of concrete at a speed of minimum 60-65
cms per year inside concrete. Catalytic in depth crystalline waterproofing system shall be able to
withstand at least 460 ft of water head pressure. Both the above characteristics shall be supported with
an international test report. The Catalytic in-depth crystalline system or equivalent shall be sprinkled at
a minimum coverage rate of 1.2 kg/sqm on the honeycomb free, retaining wall.
required
 Crystallization Waterproofing System: Negative Side
Above Basement Raft:
Providing and applying Slurry on top of PCC prior to pouring of concrete for basement raft, proprietary
“Catalytic” in depth Crystalline waterproofing system as per manufacturer’s specification and as
approved by the engineer-in-charge to permanently fix non soluble crystalline growth throughout the
capillary tracts and pores of concrete at a speed of minimum 60-65 cms per year inside concrete.
Catalytic in depth crystalline waterproofing system shall be able to withstand at least 460 ft. of water
head pressure. Both the above characteristics shall be supported with a manufacturer’s test report. The
Catalytic in depth crystalline system or equivalent shall be sprinkled at a minimum coverage rate of 1.2
kg/sqm.
Basement Retaining Wall:
Providing and applying proprietary “Catalytic” in depth Crystalline Waterproofing system as per
manufacturer’s specification and as approved by the engineer-in-charge to permanently fix non soluble
crystalline growth throughout the capillary tracts and pores of concrete at a speed of minimum 60-65
cms per year inside concrete. Catalytic in depth crystalline waterproofing system shall be able to
withstand at least 460 ft of water head pressure. Both the above characteristics shall be supported with
manufacturer’s test report. The Catalytic in-depth crystalline system or equivalent shall be sprinkled at a
minimum coverage rate of 1.2 kg/sqm on the honeycomb free, retaining wall.

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required.
 APP Membrane Waterproofing
APP Membrane
1) Providing and laying waterproofing treatment to the basements with Double layer of 4mm thick and
3 mm thick, APP modified torch applied bituminous Polyplus or equivalent waterproofing membrane,
reinforced with 180 GSM non-woven polyester matt, including overlapping, preparing the surface free
from undulations and debris, priming the damp surfaces with water based bituminous primer @ 200
gm/m² and dry surfaces with solvent base primer @ 200 gm/sq. m. and torch applying the membrane to
the surface with staggered joints. Cost to include necessary protection to the waterproofing membrane
with 3.2 mm thick chistle resistant and puncture resistant, waterproof bituboard, asphaltic protection
board, fixed by spot torching the board.
2) Providing and laying Protective Board / Protective Screed in Cement Mortar 1:4 for protection of the
membrane.
Lift Pit
Application Instruction:
1) Cleaning the joints between the flooring and walls carefully and providing and installing the Coving
Bandage to the area to overlap the joint for prevention of seepage.
2) Cleaning the concrete surface and opening the old /construction joints and sealing the same with
polymer mortar filled with stone chips and grouting joints wherever required. Providing and applying
one coat of flexible Cementitious membrane as per manufacturer’s specification.
3) Flooring: Providing and laying Metal Coba approx. 50mm thick over the surface in Cement Mortar 1:4
laid to slope with proper Wattas at junction with false squares, curing testing complete.
4) Wall: Providing and applying one coat of plaster in CM 1:4 of 15 mm thick and adding appropriate
waterproofing compound and curing the same thoroughly.
Sewage Treatment Plant
one coat of flexible cementitious membrane as per manufacturer’s specification.
3) Flooring: Providing and laying Metal Coba approx. 50mm thick over the surface in CM 1:4 laid to slope
with proper wattas at junction with false squares, curing testing complete.
4) Wall: Providing and applying one coat of plaster in Cement Mortar 1:4 of 25 mm thick and adding
appropriate waterproofing compound and curing the same thoroughly.

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Swimming Pool -New Construction with Tiles

one coat of flexible cementitious membrane as per manufacturer’s specification.
3) Flooring: Providing and laying Metal Coba approx. 50mm thick over the surface in Cement Mortar 1:4
laid to slope with proper wattas at junction with false squares, curing testing complete.
4) Wall: Providing and applying one coat of plaster in Cement Mortar 1:4 of 15 mm thick and adding
appropriate waterproofing compound and curing the same thoroughly.
Flower Bed
2) Cleaning the surface thoroughly and applying two coats of flexible cementitious membrane or
equivalent chemical waterproofing system as per manufacturer’s specification to receive brick bat coba.
3) Providing and laying screed in Cement Mortar 1:4 of 25 mm thick for protection of membrane.
 Terrace Waterproofing
 Application Instruction: Option 1
2) Cleaning the entire terrace slab thoroughly, providing and applying one coat of primer followed by
two coats Cementitious Membrane Chemical Waterproofing System as per manufacturer’s specification
3) Providing and laying brick bat waterproofing treatment over terrace including grouting 115mm thick
avg. bbc. Laid in Cement Mortar 1:5 with proper slope with 200mm effective wattas and a top layer in
Cement Mortar 1:3 with waterproofing compound, finished smooth with false squares, curing testing
complete.
4) China Mosaic: Providing and laying China Mosaic in Cement Mortar 1:6 over the terrace
waterproofing treatment.
two coats of Polyisopreme Membrane Cementitious membrane waterproofing membrane chemical
waterproofing system as per manufacturer’s specification.

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average- brick bat coba laid in Cement Mortar 1:5 with proper slope with 200mm effective wattas and a
top layer in Cement Mortar 1:3 with waterproofing compound, finished smooth with false squares,
curing testing complete.
4) China Mosaic / Tiles: Providing and laying China Mosaic / Tiles in Cm 1:6 over the terrace
2) Supplying, providing and applying waterproofing treatment with Membrane type waterproofing
methods using polymer modified Bituminous Membrane of approved makes of either Styrene
Butadiene Styreen (SBS) based or Atactic Poly Propylene (APP) (UV resistant).
average-brick bat coba laid in Cement Mortar 1:5 with proper slope with 200mm effective wattas and a
4) China Mosaic / Tiles: Providing and laying China Mosaic / Tiles in Cement Mortar 1:6 over the terrace
 Podium Waterproofing
2) Cleaning the surface of slab thoroughly, making it free of all dirt and dust, opening all visible cracks
and crevices and sealing the same with Polymer mortar. Providing and applying one coat of primer
followed by two coats of Polyisopreme Membrane waterproofing membrane or equivalent
waterproofing system to receive brick laid coba /screed.
3) Providing and laying brick bat waterproofing treatment including grouting 115mm thick average- brick
bat coba laid in Cement Mortar 1:5 with proper slope with 200mm effective wattas and a top layer in
complete.
 Kitchen / Pantry
Flooring

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2) Cleaning the surface of the floor thoroughly and applying two coats of Cementitious Membrane or
equivalent Cementitious Waterproofing System as per manufacturer’s specification to receive brick laid
in coba.
3) Providing and laying brick bat waterproofing treatment including grouting 115mm thick avg. bbc laid
in Cement Mortar 1:5 with proper slope with 200mm effective wattas and a top layer in Cement Mortar
1:3 with waterproofing compound, finished smooth with false squares, curing testing complete.
4) Providing and laying protective screed in Cement Mortar 1:4 of 25mm thick for protection of the
membrane.
Walls:
2) Cleaning the wall areas thoroughly and applying two coats of flexible cementitious membrane or
equivalent cementitious waterproofing system as per manufacturer’s specification to further receive
coat of plaster.
3) Providing and applying one coat of plaster Cement Mortar 1:4 of 25mm thick and adding appropriate
 Toilet / Bathroom without Sunk
Flooring:
2) Cleaning the toilet surface of the floor thoroughly and applying two coats of flexible cementitious
membrane or equivalent Chemical Waterproofing System as per manufacturer’s specification.
3) Providing and laying Screed in Cement Mortar 1:4 of 25mm thick for protection of the membrane.
Walls:
2) Cleaning the toilet wall areas thoroughly and applying two coats of flexible cementitious membrane
or equivalent Chemical Waterproofing System as per manufacturer’s specification to further receive
coat of plaster.
 Sunk Toilets
Application instruction:
Flooring:

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2) Cleaning the toilet surface of the floor thoroughly and applying two coats flexible cementitious
membrane or equivalent Chemical Waterproofing System as per manufacturer’s specification to receive
brick bat coba.
3) Providing and laying brick bat waterproofing treatment including grouting 115mm thick average –
brick bat coba laid in Cement Mortar 1:5 with proper slope with 200mm effective wattas and a top layer
in Cement Mortar 1:3 with waterproofing compound, finished smooth with false squares, curing testing
complete.
Walls:
1) Cleaning the toilet wall areas thoroughly and applying two coats flexible cementitious membrane or
equivalent Chemical Waterproofing System as per manufacturer’s specification to further receive coat of
plaster.
 Chajja
2) Cleaning the chajja top thoroughly, providing and applying two coats of flexible cementitious
membrane or equivalent Cementitious Waterproofing System as per manufacturer’s specification to
receive brick laid coba.
3) Providing and laying Brick Bat Pieces in 40mm thick over chajja in Cement Mortar 1:4 desired slope
and curing the same for 4 days.
4) Providing and laying IPS finish in Cement Mortar 1:4 and curing the same for 6 days.
 Service Area / Refuge Area
2) Cleaning the surface of the slab thoroughly, providing and applying two coats of flexible cementitious
membrane or equivalent Cementitious Waterproofing System as per manufacturer’s specification.
3) Providing and laying screed in Cement Mortar 1:4 of 25mm thick for protection of the membrane.
 Over Deck Insulation
1) Cleaning the entire surface thoroughly, grouting the construction joints, cracks etc. In the slab, using
cement slurry grout admixed with expandable grout additive to full saturation, thereafter, providing and

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applying one coat of flexible cementitious membrane or equivalent Cementitious Waterproofing System
on the RCC surface and on the vertical surface, up to 300mm including making fillets at the junction of
horizontal and vertical surfaces.
average brick bat coba laid in Cement Mortar 1:5 with proper slope with 200mm effective wattas and a
3) Providing and laying Foamular Metric extruded polystyrene thermal insulation layer of 50 mm thick,
stuck on the surface using suitable adhesive with shiplap joint etc. complete.
4) Providing and laying screed for protection in Cement Mortar 1:4 of 50mm thick.
5) Providing and laying separation sheet of chop Stand Geotextile Mat of 225 GSM over the extruded
polystyrene foam.
6) Providing and laying China Mosaic /Tiles in Cement Mortar 1:6 over the deck insulation membrane.
 ROOF GARDEN / PODIUM TERRACE
 Cementitious Membrane Waterproofing
two coats of cementitious Membrane waterproofing membrane chemical waterproofing system as per
manufacturer’s specification.
avg. bbc laid in Cement Mortar 1:5 with proper slope with 200mm effective wattas and a top layer in
complete.
4) Providing and laying Non Root Penetrating PVC Preformed membrane.
5) Providing and laying drainage board.
6) Providing and laying separation sheet of Chop Stand Geotextile Mat of 225 GSM over the extruded
polystyrene foam.
7) Providing and laying substrate.
8) Providing and laying Plants.
 Polyisopreme Membrane waterproofing

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two coats of Cementitious Membrane and waterproofing membrane as chemical waterproofing system
as per manufacturer’s specification.
average brick bat coba laid in Cement Mortar 1:5 with proper slope with 200mm effective wattas and a
4) Providing and laying Non Root Penetrating PVC Preformed membrane.
5) Providing and laying drainage board.
6) Providing and laying separation sheet of Chop Stand Geotextile mat of 225 GSM over the extruded
polystyrene foam.
7) Providing and laying substrate.
8) Providing and laying Plants.
Records :
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APPLICATION PROCEDURE FOR NON-

SHRINK GROUT FOR STRUCTURAL

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TABLE CONTENT
SR.NO DESCRIPTION
1. PURPOSE
2. LIMITATIONS
3. PROPOSED MATERIAL
4. REFERENCES
5. DEFINATIONS
6. CLASSIFICATION OF GROUTS
7. TOOLS / EQUIPMENTS
8. EXECUTION
9 MATERIAL HANDILING / STORING
10 HEALTH, SAFETY AND ENVIRONMENT

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NON- SHRINK GROUT FOR STRUCTURAL

1. PURPOSE:
This procedure defines the method and practices that will be used for non-shrink grout application
such as below structural base plates, machine pads and other similar structures where non-shrink
grout is required.
2. LIMITATIONS:
This procedure should be applicable for the duration of the project as per the current base-line
schedule or any approved revisions to the schedule.
3. PROPOSED MATERIAL:
SIKA GROUT 114 - For grouting application with 75mm maximum thickness
BASF Master Flow 950 – For grouting with required thickness ranging from 20mm thickness and to a
maximum
depth of 100mm.
DURAGROUT & Other Similar Grout Material approved by CLIENT
4. REFERENCES:
 SIKA GROUT 114 Data Sheet
 DURAGROUT Data Sheet
 BASF Master Flow 950 Data Sheet
 SAES-Q-010 – Cement Based, Non-Shrink Grout for Structural and Equipment Grouting
 PIP STS03601 - Epoxy Grout Specification
 Project Specification SECTION 03600 - GROUT
 ACI 351.1R-12 - Report on Grouting between Foundations and Bases for Support of Equipment
and Machinery
 Project Schedule “Q”
5. DEFINITION:
Grout - is a particularly fluid form of concrete used to fill gaps. Grout is generally a mixture of water,
cement, and sand, and is employed in pressure grouting, embedding rebar in masonry walls,
connecting sections of pre-cast concrete, filling voids, and sealing joints. Grout is distinguished by its
high viscosity

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Non-Shrink Grout - is a hydraulic cement grout that produces a big volume that, when hardened
under stipulated test conditions, is greater than or equal to the original installed volume; often used
as a transfer medium between load-bearing members.
Flowable Grout - a cementitious grout consistency with a flow of 125 to 145 by the flow test in
accordance with the applicable provisions of the ASTM C1437-07 & SANS test method; the flow
expressed as a percentage of the original base diameter after five drops of the flow table in 3
seconds.
Plastic Grout - a cementitious grout consistency with a flow of 100 to 125 by the flow test in
accordance with the applicable provisions of ASTM C1437-07 test method & SANS; the flow
calculated after five drops of the flow table in 3 seconds.
Working Time—time in which the grout can be placed.
Fluid Grout - a cementitious grout consistency with a time of efflux of 10 to 30 seconds when tested
by the flow cone procedure of the ASTM C939-10 & SANS test method.
Grout Shoulder—the portion of the grout that extends beyond the base plate toward the edge of
the concrete foundation.
Cure Time - time after setting in which chemical and physical changes in the grout produces long-
term durability strength and serviceability.
6. CLASSIFICATION OF GROUTS:
 Class 1 Grout – used for precision, non-shrink grouting of structural base plates, anchor
bolts, columns,
And pre-cast members.
 Class 2 Grout – used for all non-precision grouting such as pipe sleeves and other
applications were
Non-shrink characteristics are not mandatory.
7. TOOLS/EQUIPMENT:
Any tools and equipment necessary to complete the work according to the requirements of PIP
REIE686 and the
Product recommendation.
8. EXECUTION:
1. Surface Preparation
 Concrete foundations shall be cured for a minimum of 7 days before surface preparations
for grouting.
 Remove laitance and oil-soaked or damaged concrete with chipping hammer to sound
fractured aggregate, or to a minimum of the top 1 inch (25 mm) of concrete. Bearing
surfaces to be grouted shall be roughened to expose coarse aggregate (Proj. Specs.).
 When surface chipping is complete, remove all dust and loose particles with clean, dry, oil-
free air.
 Concrete surfaces in contact with the epoxy grout shall be clean and dry at time of

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placement. Air used for blowing shall be clean, dry, and oil -free.
 After cleaning, protect the foundation surface from contamination by applying protective
sheeting.
 Suitable shelter or enclosures shall be provided to protect the foundation and baseplate
from direct sunlight, dew, rain, or other inclement weather. During cold weather, adequate
enclosures and heating shall be provided to maintain foundation and baseplate
temperature within the acceptable range specified by the grout manufacturer. This
temperature shall be maintained until the grout has cured or until directed by the grout
manufacturer.
 Pre-soak all concrete surfaces to be grouted for 24 hours prior to a placing Class I and Class
II, grouting. (Proj. Specs.)
2. Formwork
 Grout Formwork, where required, shall be constructed with adequate strength, rigidity and
required dimensions to permit grout placement and avoid leakage.
 Attach grout forms to concrete with drilled anchors or other method when approved by
the buyer. Power nailing is not permitted.
 Apply three coats of paste wax (if found necessary) to the inside surface of forms or use
other methods as recommended by the epoxy grout manufacturer to prevent grout
adherence. Oil or liquid wax is not permitted.
 Install 1-inch (25-mm) 45° chamfer strips at each vertical corner and at the horizontal
surface of the grout forms.
 Seal all form joints and interface between forms and concrete foundation using grout
manufacturer’s recommended sealant.
 Anchor bolts shall be protected by sleeves, and exposed threads shall be
 Wrapped with duct tape to prevent adherence of epoxy grout. Anchor bolt sleeves shall be
extended to the underside of the mounting plate, or the area from the top of the anchor
bolt sleeves and the bottom of the mounting plate shall be sealed to exclude epoxy grout.
3. Installation of Epoxy Grout
 Prior to grouting, concrete repair have been performed in accordance with SAIC-Q-1062 as
based on SAER-5803
 An adequate quantity of grout shall be on hand before starting to mix and place grout. No
partial units of epoxy, resins, hardener, or aggregate shall be used. The ratio of
components shall not be varied, and solvent shall not be added to change the grout
consistency.
 Grout placements shall be started at one end of the forms, and the cavity shall be filled
completely while advancing toward the other end to prevent air entrapment.
 The forms shall be checked for grout leaks frequently. Leaks will not self-seal and may
cause voids in the grout if not stopped. All leaks shall be sealed to prevent voids from

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forming in the grout.


The grout shall be checked for voids after the grout has cured. Any voids shall be filled
according
to the epoxy grout manufacturer’s instructions.
 Exposed expansion joints shall be sealed with the epoxy grout manufacturer’s
recommended sealant.
 For standard temperature testing, maintain the grout mixture and the testing equipment at
a temperature of 73.4 +/- 5°F (23 +/- 3°C). (ASTM C 1107, Sec. 8.1.2)
4. Curing
 When the grout's water/cement ratio is 0.4 or less, the grout shall be given a continuous
water cure (covered by wet burlap and 0.15mm polyethylene) for a minimum of 7 days.
(ASTM C309, Sec. 5.1)
 Curing compounds if allowed by project specifications, shall have test reports or certificate
showing that it is in compliance with ASTM C309.
5. TESTING
 Sampling and Testing shall be performed by Approved testing laboratory.
6. INSPECTION/ACCEPTANCE REFERENCES
 Work acceptance shall be in accordance to Approved Application Procedure, Product
Recommendations, Applicable client Standards and SANS and Checklist.
9. MATERIAL HANDLING/STORING:
 Handling and storing shall be as per recommendation by the SIKA GROUT 114, BASF Master
Flow
950 & DURAGROUT Product instructions and applicable CLIENT Standards.
10. HEALTH, SAFETY and ENVIRONMENT:
 Health, Safety and Environment issues shall be guided by approved safety procedures &
client Standard.
 Work area to be kept clean, safe and easily accessible
 Appropriate PPE shall be worn at all times
 Safety talk shall be conducted to remind the workers about the risk involved before
commencing the activity.
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METHOD STATEMENT
FOR
DOOR FRAMES & SHUTTERS
 Frames for Doors / Windows / Openings

Raw Materials:

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A) Wooden Doors / window frames:

1) Door frames shall be checked for uniformity in thickness, right angles from inside surface, straightness &
warpage of members, if any.
2) Three exposed surfaces of frame shall be checked for smooth planning.
3) All door frames shall be provided with knee braces and bottom patti. Also joinery and filling of joints shall be
satisfactory. Frame shall be machine papered and have satisfactory finish.
4) Depth of rebate should be as per recommendation of Architect (Depth of rebate in door-frame ideally shall be
minimum 15 mm and in window /ventilator frames shall be minimum 12 mm). Rebates shall be uniform through
the length of frame.
5) Thickness of tenon shall be 1/3 rd that of member and width of tenon shall not exceed five times the
thickness. Horns shall project 50/100 mm. As far as possible horns should be avoided.
6) Door frames shall be provided with minimum 3 nos. of holdfasts on either side. Holdfast being made of MS
flats 25 mm. wide, 230 mm long and 2 mm thick. Ends of the hold fasts shall be split. One holdfast shall be
provided at centre whereas other two shall be provided at 30 cms from top and bottom ends of the frame. For
main door, minimum 4 nos. of holdfast should be provided.
7) All door frames shall be applied with primer (for paint) and multan matti (for polish) immediately after their
receipt at site.
B) Natural stone door frames:
1) Vertical as well as horizontal members shall be in one piece, without cracks or flaws.
2) Rebates shall be recommended same as of wooden door frames. Polish within the rebate shall be same as that
for the rest of frame.
3) Location /diameter of holes for fixing Aldrops/ Tadipattis shall be as per drawings.
4) Rounding done shall be smooth with proper finish.
C) Frames for openings (wooden):
1) Wooden sections shall be as per recommendation of Architect and of full size. (Minimum required section size
ideally shall be 4” X 2.5” for opening size up to 1 mtr. and 5” X 2.5” for opening size greater than 1 meter up to 2
meter).
2) Wood shall be fully seasoned, crack free and straight.
3) Wood shall have parallel grain structure and the surface should be dry and without oily secretions.
4) Moisture content in wood shall not exceed 14 % when checked with moisture meter.
5) Single section shall not have more than 3 knots.
Procedures for Fixing of Frames and Shutters:
Frames for doors/ windows/ openings
a) Pre fixing procedures:

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1) Necessary architectural drawing showing details of doors, windows and openings shall be available on site.
2) Door frames which are found to be out of plumb shall be planed properly to bring it into plumb.
3) Bottom portion of vertical members of frame shall be marked with paint, indicating level up to which they are
to be embedded in the floor bedding .This shall be achieved by taking floor tilling level pads.
4) Portion of door frame to be embedded in floor as well as face of the frame in the contact with masonry shall
be applied with two coats of a bituminous paint (Black Japan or equivalent) and remaining sides @ bottom 6” (6”
from slab level) shall be applied with transparent protective coat (wood guard).
5) Bottom portion of vertical members of frame shall be provided with metal pin for proper anchorage in to the
floor bedding.
6) Application of one coat of wood primer / multan matti shall be ensured on all frames before erection.
7) Opening shall be finished to correct dimensions, level, plumb and diagonals.
8) If opening sizes are found smaller than required, the same shall be brought to correct dimensions by
roughening the surface and finishing by plastering neatly in line and level.
9) If opening sizes are found larger than required, the same shall be chipped off using round wheel cutter and
chisel. Undulations shall then be finished by plastering neatly in line and level .
b) During fixing procedure:
Door /window frames:
1) Door frames shall be fixed along with masonry work, with level of frames matching with level pads of finished
plaster level. Window frames shall be fixed after completion of internal plaster.
2) If bends are observed in the frames, wedges shall be inserted between frames and masonry surface to remove
bends.
3) Holdfast shall be embedded in masonry with M-15concrete.
4) Holdfast, if required to be fixed to concrete surface viz. column, then they should be fixed by drilling holes in
concrete. Nailing in concrete shall be avoided. Coach screw can be used for the same. Coach screw of approved
cross section and length sunk within the frame and capped by plugging with the same timber material.
5) Knee braces for frames shall not be removed unless frame is fixed satisfactorily.
6) If natural stone frames are required to be fixed over plastered surface, then the plastered surface shall be
roughened adequately. Sand faced plaster shall be hacked, whereas neeru / sanla surface shall be grinded.
7) Coat of epoxy with marble chips / sand shall be applied at the back of natural stone frame, at least one day
prior to frame fixing.
8) In case of natural stone frames, vertical and horizontal frame members shall be joined with neatly finished hair
line joints. White cement shall be used in case of marble frames where as gray cement shall be used in case of
granite stone frames.
Frames for opening:
1) Section shall be cut to required size, and planed perfectly to remove any bends along the length of sections.

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2) Offsets for shutters shall be machine cut and planned to have a perfect straight cut as per requirement.
3) Holdfast shall be of MS / GI 3mm thick and coated with red oxide.
c) Post fixing procedures
Door / window / opening frames
1) After fixing of frame, the entire frame shall be again checked for plumb, level, right angle and necessary
rectification shall be carried out if required.
2) Cover moulding should be provided at the junction of plaster surface and wooden frame.
 Shutters for Doors
Wooden flush – Solid core
1) Door shutter brand shall be checked for approved make as per specification.
2) The type of shutter, thickness and surface finish on both sides as well as other dimensions of shutters shall be
checked for correctness as per requirement.
3) Moisture content in the wood shall be checked by moisture meter, and moisture content within the wood
shall not exceed 12% asper IS 2202(Part1):1999
4) Timber used for door shutters shall be well seasoned and without any cracks.
5) Knots, if presents, shall not be more than 3 per shutter.
6) Shutters with bends at corners shall be rejected.
7) Immediately after receipt, door shutters shall be applied with wood primer on all sides including edges, except
decorative veneer surface.
Other Accessories
a) Lipping Patti:
Lipping Patti shall be in teak wood and in one piece. Double lipping Patti shall not be used to increase the door
shutter size.
b) Primer:
Primer to be applied to door shutters shall be as per recommendation of paint manufacturer/ as specified by
Architect.
c) Putty:
Multan matti shall be used as primer; otherwise putty shall be made by mixing whitening powder with linseed oil
with approved brand and manufacturer’s specification.
d) Bitumen paint:
Anticorrosive paint shall be bituminous, black Japan is preferable.
e) Door accessories:

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1) Door accessories like Aldrops, Tadipattis, Tower Bolts, Door handles, Hinges and stoppers shall be as per
Architect’s specifications.
2) Sizes shall match with those indicated on drawings.
3) Hinges of brass or stainless steel are recommended.
4) Accessories shall be chosen at random for checking of proper functionality.
Test on door shutters:
A) Dimensional checks (non destructive test):
 Measurement of length and width,
 Measurement of Thickness,
 Square ness,
 Twist.
B) Steel ball impact test,
C) Destructive tests:
 End emersion test,
 Glue adhesive test,
 Knife test.
In additional to above, following tests shall be carried out in laboratory for wood and door shutters, conforming
to IS 2202(Part 1):1999
 Varying humidity test,
 Slamming test,
 General flatness test,
 Shock resistance test,
 Edge loading test,
 Local plainness test,
 Flexural test,
 Bulking test,
 Screw pull out test.
Procedures
a) Pre Fixing Procedures for door shutters.
1) If required, Lipping Patti shall be provided on shutter. Lipping Patti shall be of teak - wood and in one piece.
Joint shall be provided only at corners.
2) Primer and one coat of specified paint as specified by Architect shall be applied to all sides of shutter including
lipping patti before fixing any fitting on shutter.
b) During fixing procedures for door shutters
1) Type and size of hinges shall be depending upon weight, thickness and type of opening of shutter as specified
by Architect.

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2) Number of hinges shall be minimum 4 nos. for main door. Position of hinges shall be 1st at top, 2nd at 600 mm
from top, 3rd at centre and 4th at bottom or equidistant or specified by Architect.
3) Screws in hinges shall be driven with the help of screw driver and not hammered.
4) Care shall be taken to see to it, that automatic door closer, if fixed to the door shall not touch the wall, during
operation.
5) Door shutter shall be fixed in such a way that, uniform gap of 3 mm. is maintained between door frame and
door shutter on a top as well as sides. Also 5 mm. gap shall be maintained between bottom of shutter and
Finished Floor Level (FFL).
6) PVC Sheet shall be fixed with suitable adhesive to either side of door shutter for doors in toilet and terrace if
specified by Architect.
7) All other door accessories like Aldrops, tadipatties, tower bolts, door handles, hinges; eye piece, magnetic door
stopper and latch shall then be fixed as per drawing at specified positions.
8) Checking of latch and guidelines should be followed as per manufacturer’s specifications for its position and its
fixing.
c) Post fixing procedures for door shutters
After fixing of door shutter at least one Aldrops shall be fixed from outside for locking the door.
Doors / Windows /Openings Frames and Door Shutters.
Tests for wood satisfactory Accepted
Tests for door shutters satisfactory Accepted
Holdfasts for frames as specified As per recommendation
Hold fasts for door shutters as specified As per recommendation
Fixing of hold fast as specified As per recommendation
Door frame in plumb Accepted
Door shutter in plumb Accepted
Size and no. of hinges provided As per recommendation
Antirust screws provided in hinges Accepted
Screws not hammered inside hinges Accepted
Lipping patti in one piece Accepted
Gaps between door shutter and frame 3 mm. uniform
Gaps between door shutter and FFL 5 mm. uniform
Operation of night latch and other accessories Smooth

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Records :
ITP Reference No :

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SANITARY WARES, FITTINGS &
ACCESSORIES INSTALLATION
INSTALLATION SANITARY WARES, FITTINGS & ACCESSORIES
1. PURPOSE
The method statement of sanitary wares, fittings & accessories installation describes the method of
supply and installation works executed in a safe manner and in accordance with the project requirements.
All quality assurance/control activities are carried out in a systematic manner where works are inspected
to specified conformance which will be verified and documented for the project.

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2. REFERENCES
This method statement is subject to the requirements as stated in the following regulatory & statutory
documents, applicable standards, specifications, and building codes:
Project Specification – Plumbing Fixtures (Water Closet/Bidet/Hand Wash Basins/Sinks/Bath
Tubs/Hand Spray/Shower Sets/Floor Drains)
Relevant Sections of IPC
Project approved IFC drawings & materials
Approved HSE Plan
3. Sanitary wares, fittings & accessories installation
Storage of Materials
Loading and unloading of delivered plumbing fixtures and accessories and relevant materials shall be
carried out manually or mechanically.
Handling to be strict as per manufacturer’s recommendation and as necessary, in a protective packing,
crating, and covering. Retain the original protection by the manufacturer until the area for installation is
ready.
On the receipt of material, a visual check will be made to ensure that the components comply with the
approved schedules, packing list, and installation drawings.
The shifting activity to be planned.
Store sanitary fixtures on elevated platforms in a dry location.
If plumbing fixtures and accessories are not to be installed immediately after the delivery at site, store
plumbing fixtures on elevated platforms and dry location without hindering the safety of the personnel.
The storage area to be identified
All the equipment & accessories that will be transported on the site will be inspected thoroughly and
travel on the specified routes of the contractor and unload on the specified place near the workplace.
Extra precautions will be implemented during transporting all materials and equipment and carefully
following all the traffic signs while inside the project site.
4. Preparation
Verify if the area for installation is ready & works related to other disciplines are completed prior to
starting the installation.
Inform in advance to the responsible person if any foreseen problem occurs.
Examine roughing-in for potable, hot- and cold water supply piping systems; soil, waste, and vent piping
systems; and supports. Verify that locations and sizes of piping and locations and types of supports match
those indicated, before installing and connecting fixtures. Use manufacturer’s roughing-in data when
roughing-in data are not indicated.
Examine walls, floors, and cabinets for suitable conditions where fixtures are to be installed.

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Do not proceed until unsatisfactory conditions have been corrected.

5. Installation of Plumbing Fixtures
Assemble plumbing fixtures and trim, fittings, faucets, and other components according to
manufacturers’ written instructions.
Install fixtures level and plumb according to manufacturers’ written instructions, roughing-in drawings,
approved architectural layouts, and referenced standards.
Install wall-hanging, back-outlet water closets with support manufacturer’s tiling frame or setting gage.
Install toilet seats on water closets as specified
6. Install wall-hanging, back-outlet urinals with gasket seals
Fasten wall-hanging plumbing fixtures securely to supports attached to building substrate when
supports are specified, and to building wall construction where no support is indicated.
Fasten floor-mounted fixtures to substrate. Fasten fixtures having holes for securing fixture to wall
construction, to reinforcement built into walls.
Fasten recessed, wall-mounted fittings to reinforcement built into walls.
Fasten wall-mounted fittings to reinforcement built into walls.
Fasten counter-mounting plumbing fixtures to casework.
Secure supplies to supports or substrate within pipe space behind the fixture.
Set shower receptors and mop basins in leveling bed of cement grout.
Install individual stop valve in each water supply to fixture. Use gate or globe valve where a specific
stop valve is not specified. Omit stop valves on supplies to emergency equipment
Install water-supply stop valves inaccessible locations.
Install faucet laminar-flow fittings with specified flow rates and patterns in faucet spouts when faucets
are not available with required rates and patterns. Include adapters when required.
Install shower, flow-control fittings with specified maximum flow rates in shower arms.
Install traps on fixture outlets. Omit traps on fixtures having integral traps. Omit traps on indirect
wastes, except where otherwise indicated.
Install disposers in sink outlets. Install switch where indicated, or in-wall adjacent to sink if the location
is not indicated.
Install escutcheons at the wall, floor, and ceiling penetrations in exposed, finished locations and within
cabinets. Use deep-pattern escutcheons were required to conceal protruding pipe fittings.
Seal joints between fixtures and walls, floors, and counters using sanitary-type silicone sealant
according to sealing requirements specified by the manufacturer.
The location, elevation, orientation, and type of fixtures shall be as per approved architectural layouts,
Materials submittals & manufacturer’s datasheets.

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7. Connections
Drawings indicate the general arrangement of piping, fittings, and specialties. The following are
specific connection requirements:
Install piping connections between plumbing fixtures and piping systems and plumbing equipment
specified in the approved shop drawings/details
Supply and Waste Connections to Plumbing Fixtures:
Refer to product sheets/detail drawings for fitting sizes and connection requirements for each
plumbing fixture.
Supply and Waste Connections to Equipment Specified in Other Sections:
Connect equipment with supply inlets, supply stops, supply risers, and traps specified in product data
sheets/detail drawings. Use fitting sizes required to match connected equipment. Connect fittings to
plumbing piping.
8. Manpower Requirement
Subject to main contractors program and scope/area available for MEP activities, but not limited to
below:
Chargehands
Plumbers
Helpers
9. Material Requirement
Ensure material being used are of approved manufacturer/material submittal from project vendor list
and of quality as specified.
Approved type & make of sanitary ware fixture & fittings, approved carriers for fixtures recommended
type of sealant, etc.
10.Tools & Equipment
Platform ladder
Step ladder
Hand Tools (Hammer, wrenches, L-Key set)
Spirit Level
Battery operated hand drilling machine
Hammer Drilling Machine
Sealant Gun
Spanner set box

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Allen key set

Palletizer Jack
Records :
ITP Reference No :

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EPOXY RESIN COATING WORKS FOR

FLOOR
EPOXY RESIN COATING WORKS FOR FLOOR

1. PURPOSE
The method statement for epoxy resin coating for the floor defines the sequence, quality control
procedures and safety guidelines for epoxy flooring works.
This work method statement covers activities related to epoxy floor coating works on various locations
as applicable and excluding traffic/vehicular areas.
2. Definitions
Developer/Client-xxxx
Supervising Consultant-xxxx
Main Contractor-xxxx
QC-Quality Control
HSE-Health Safety & Environment
PPE-Personal Protective Equipment

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3. References
Project Specifications
Contract Specifications
Architectural Specifications
Epoxy Resin Floor Coating
Health and Safety Plan
Construction and Environmental Management Plan
3. Responsibilities
1. Project Manager
Responsible for accomplishing the stated objectives which include creating clear and attainable
objectives, building the requirements, and managing the cost, time, scope, and quality.
2. Site Engineer
Supervise operations in accordance with the approved method statement, shop drawings,
specifications, approved material submittal, and schedules to achieve the acceptance of the
deliverables.
3. Site Foreman
To liaise with the Site Engineer and Supervisor for the work execution.
4. HSE Manager
Health, safety, and environmental (HSE) managers generally plan, coordinate and implement issues
and directives within the organization.
They ensure safe environmental working conditions for all employees.
5. HSE Supervisor/Officer
The Safety Engineer should be full-time at the site and should frequently visit all the ongoing activities.
All safety violations and on-conformance of the plan shall be registered and immediate action will be
done in coordination with the Site Engineer.
6. Scaffolding Manager/Supervisor
Ensuring safe access is provided for scaffolders’ jobs.
Ensuring that all his foremen, construction team leaders, construction staff, and workers are
conforming to work safety regulations and are Third Party Certified (TPC).
Ensuring that all scaffolds are erected according to scaffold methods.
Ensuring that scaffold schedules are met and still working within the safety requirement.
Ensuring that material and workers are available to meet the scaffolding requirements.
Ensuring that all documentation adheres to ToolBox Talks, Harness Inspection, Work Request System,
Scaffolding Tagging System, and Safety reports.

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7. QA/QC Engineer should ensure are ongoing as per specifications and the document should follow as
per ITP.
8. Tradesmen (Workers)
The workers should aware of the nature of the job and should know the approved system, however,
the tasks and the quality must be ensured by the site engineer and QA/QC Engineer.
4. Resources
4.a Tools and Equipment
Approved scaffolding-For working at height
Confined space rescue-For emergency rescue
Multi-gas detector-For gas test inside confined space
Lighting facilities-For lighting of job area
First aid box-For emergency first aid
Exhaust fans-For ventilation
Barricading and fencing-For preventing unauthorized access
Protective clothing (gloves, overalls, goggles, and face masks)-For safe working
Slow speed drill, 400 or 500 rpm, plus mixing paddle and mixing vessel-For mixing
Grinder & vacuum cleaner-For surface preparation / floor preparation
Rollers, scrappers & brushes-For painting application
4.b Workforce
Site Engineer
QA/QC Engineer
HSE Officer
Team Leader/Foreman
Technicians
Applicators
4.c Light Tools
Drill Machine
Slow speed drill machine
Surface Grinder
Hand Grinder
Vacuum Cleaner / Dust Collectors
Industrial vacuum machine

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4.d Materials
Epoxy Paint Application–Sikafloor 264 – Approved material
Floor Putty–Sikafloor PS
Aggregates–Sikadur 507
1. Methodology-Epoxy Coating Works for Floor
General
This methodology specifies the requirement for 2 coats of epoxy flooring in concurrence with the
manufacturer recommendations, requirements, and other related detail specifications.
The working area will be barricaded and restricted from the entry of unauthorized personnel.
It will be properly illuminated and necessary warning signs to be installed in the proper location.
All scaffolding activities and ladders for access and egress will be erected by certified scaffolders. All
erected scaffolding access and egress will be inspected and tagged prior to use.
The relevant permits to be fully complied with by the working team prior to commencing activity and
ensure its validity.
Part mixing is acceptable as per requirements. However, once the pack is opened and not in use this
must be tightly sealed with the lid (material to be checked prior to the next usage).
All workers to be involved in the activity will receive proper information, instructions, training, and
adequate supervision during the activity. All workers will be briefed as well with the safe system of
task and procedure along with the use of proper PPE’s and emergency rules.
Relevant entities which might need protection include any type of work in the area vicinity of work,
service access, or discharge path.
2. Procedures-Surface Preparation
The existing area which requires refurbishment must be prepared to ensure a strong adhesive bond
between the first coat and the existing concrete area.
Clean the surface by grinding means of heavy-duty substrate grinders to remove the previous coating,
laitance, and other contamination such as oil, grease, mortar and paint splashes, etc. (Any sharp edges,
protrusions, imperfections, or surface undulations in levels to be ground and made well by the client
free of charge.)

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Vacuum clean to remove the dust and other loose particles.

Before application, all surfaces must be dry and free from oil, grease, decayed matter, moss or algae
growth, and general curing compounds. All such contamination and laitance should be removed by the
use of mechanical means.

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The surrounding surfaces which are not to be coated but which may be affected by the coat
application should be protected.
Fill all exposed blow holes, routed out cracks, etc. with SIKAFLOOR PS up to a rate of 0.1 to 0.2 kg/m²
to obtain a uniform surface of texture similar to medium sandpaper.
3. Substrate Pre-treatment
The concrete substrate must be sound and of sufficient compressive strength (minimum 25 N/mm 2)
with a minimum pull-off strength of 1.5 N/mm 2.
The substrate must be clean, dry, and free of all contaminants such as dirt, oil, grease, surface
treatments, etc.
Concrete substrates must be prepared mechanically using abrasive blast cleaning (blasting method) or
scarifying equipment
to remove cement laitance and achieve an open textured surface.
Weak concrete must be removed and surface defects such as blowholes and voids must be fully
exposed.
Repairs to the substrate, filling of blowholes/voids and surface leveling must be carried out using
appropriate products from the Sikafloor, Sikadur, and Sikagard range of products.
All dust, loose and friable material must be completely removed from all surfaces before application
of the product, preferably by brush or industrial vacuum.
4. Epoxy Paint (Sikafloor 264) Implementation
SIKAFLOOR 264 is a two-part High-build Solvent Free Epoxy Coating. Suitable for use in hot and
tropical climatic conditions.
Stir separately components A and B of SIKAFLOOR 264 well with an electric mixer, add the full contents
of component B into component A, and mix with a slow speed mixer (300–400 rpm) for at least 2
minutes until a homogeneous mixture is achieved.
Place mixed material into a clean container, mix again for one minute.
Prior to the application of epoxy – SIKAFLOOR 264, the surface should be thoroughly cleaned to
remove any traces of dust or other debris.
Apply the primer to the prepared surface prior to utilization of floor putty.
Afterward, apply the epoxy mixed material by roller using the consumption of 0.25 kg/m², taking care
to ensure good wetting of the substrate but avoiding puddles on the surface. Allow drying.
Followed by the second coat of SIKAFLOOR 264 using a roller or brush at a rate of 0.25 kg/m² ensuring
that the surface is fully covered and that no ponding of the material occurs. The coat should be applied
evenly over the floor surface to ensure a regular film thickness.
The minimum interval between the coats is as follows:

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Freshly applied SIKAFLOOR 264 should be protected from dampness, condensation, and water for at
least 24 hours. Due to the nature of the activity, for damages on the finished surface, rectification will
be done as per manufacturer recommendation which will depend on the type of damage.
Droppings and other foreign matters on different surfaces will be removed and cleaned immediately
after the completion of each application.
5. Thickness and Application Rate
Effective Covered Area
Sikafloor PS-0.200 kg/m²
Sikafloor 264 (1st coat)-0.250 kg/m²
Sikafloor 264 (2nd coat)–0.250 kg/m²
6. Types of Damages and Remedies
High spots to be removed by means of grinding by the use of the grinding machines.
All dust, loose and friable material must be completely removed from all surfaces before application of
the product, preferably by brush and/or industrial vacuum.
The substrate and uncured floor must be at least 3°C above the dew point to reduce the risk of
condensation or blooming on the floor finish.
Low temperatures and high humidity conditions increase the probability of blooming, thus weather
conditions should be monitored always prior to any kind of coating.
Over mixing must be avoided to minimize air entrainment, since pot life of any kind of epoxy to be
followed as per technical data sheet thus the area to be calculated prior to mix the material else it will
lead to overconsumption or wastage.
Damage area should be found and analyze the root cause for repair, then the area to be repaired
should be square cut and repeat the same application procedure, however, due to material property
the color difference may occur.
7. Risk Assessment-Method Statement for Epoxy
Please refer to the attached document in Appendix A.
8. Inspection and Test Plan
Refer to Appendix B for Inspection & Test Plan
9. Drawings
Not applicable since the coating applications will be followed as per specifications.
10.Pre-Start Safety Briefing Arrangements
Refer to Risk Assessment on Appendix A.
11.Protective and Safety Equipment
All workers involved will be equipped with adequate PPE as stated below:
a. Safety Helmet with company logo

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b. Safety Boots
c. High Visibility Vest
d. Safety Goggles
e. Hand Gloves
f. Coveralls
16. Information to Personnel
a. Safety Induction
b. Job Training
c. Superintendents Notices/Memos
d. Toolbox Talks
e. STARRT Card
17. Supervision and Monitoring Arrangements
Construction Manager
He is in charge of all construction activities. Schedule the site in logical steps and budget time required
to meet deadlines. Inspect and review works to monitor compliance with building and safety codes
and other regulations.
Site Engineer
The Site Engineer will evaluate the number of materials consumed by each trade to be compared
against the planned quantity.
Site Foreman
A site foreman is responsible for supervising the workers and also doing actual activity. The foreman
monitors employees to make sure that the work is done efficiently and within quality standards.
Chief Surveyor
A Chief Surveyor ensures that surveying data are collected and recorded accurately and that all
company guidelines are followed by crew members.
QA/QC Engineer
The QA/QC Engineer will monitor whether the installation activities are conforming to the required
quality otherwise he should notify the Site Engineer should he find non-conformance to the ongoing
construction activities.
The Site Engineer should immediately rectify the work to avoid receipt of non-conformance from the
quality engineer.
HSE Engineer
The Safety Engineer will be full-time at the site and will frequently visit all the ongoing tasks. All safety
violations and non-conformance of the HSE Plan will be registered and immediate action will be done
in coordination with the Site Engineer.
Scaffolding Manager/Supervisor

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FORMATE ID:
MES/MS/PRJ-001
REV NO.: 00
MINING SERVICES &

EFFECTIVE DATE:
SUPPLIES
DOCUMENT
METHOD STATEMENTS
TITLE:
Page 232 of 232

CONTRACTOR
NAME:
Ensuring that all his Foremen, Team Leaders, and workers are conforming to safety regulations and are
Third Party Certified (TPC).
Ensuring that all scaffolds are erected according to scaffold methods.
Note: Site Engineers/HSE staff should have access on-site to civil method statements and risk
assessment
18. Environment and Quality Issues
Precautionary Measure
All precautionary measures will be briefed to all workers prior to commencing the activity.
Disposal Requirements
All waste will be disposed of as per the Construction and Environmental Management Plan, and as per
government-approved disposal areas.
Inspection, Test, and Sampling
Request for Inspection and Testing will be submitted prior to and after execution of works.
Quality Assurance Requirements Table
Ensure that work is executed as per approved shop drawing, method statement projects, and records
are generated referring to approved ITP.
Best management practices should also be considered which may be stated by product manufacturers
or suppliers.
Authority requirements will take precedence over all requirements in case authority approval is to be
secured.
For non-authority approval activities, the approved latest specification will take precedence.
It is to ensure that regular toolbox pieces of training-related work quality are conducted and records
are maintained
REFERENCES:
Clause No. 7.5.1 of ISO-9001:2015

Section 7.0 of IMS Manual
************ ************

Decisions
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Step Process

MSS-METHOD STATEMENTS Mitendra

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FORMATE ID:

MINING SERVICES &

MINING SERVICES & SUPPLIES RETURN TO INDEX

Responsible Person Signature Date

MSS PROJECT MANAGER

MSS QA/QC CO-ORDINATER

DRA SITE CIVIL SUPERVISOR

DRA QA/QC CO-ORDINATER

KCSA SHE MANAGER

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Start/End Process Flow Process Alternate Document Information/Data

Property of MES – Approved (Controlled document in Document Repository)

MINING SERVICES &

MINING SERVICES & SUPPLIES RETURN TO INDEX

Use Standard Flow Chart Symbols in Process approach Flowchart:

Start/End Process Flow Process Alternate Document Information/Data

Property of MES – Approved (Controlled document in Document Repository)

MINING SERVICES &

MINING SERVICES & SUPPLIES RETURN TO INDEX

GENERAL NOTE FOR

HEALTH SAFETY & ENVIRONMENTAL

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MINING SERVICES &

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HEALTH SAFETY & ENVIRONMENTAL

1. Health & Safety

 Employees to be hook up at all times.

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MINING SERVICES &

MINING SERVICES & SUPPLIES RETURN TO INDEX

 All scaffolding to be erected and dismantled as per KCSA Safety Plan.

 All scaffolding to be erected by trained and appointed scaffold erectors.

 All scaffolding to be inspected by trained and appointed scaffold inspector.

Use Standard Flow Chart Symbols in Process approach Flowchart:

Start/End Process Flow Process Alternate Document Information/Data

Property of MES – Approved (Controlled document in Document Repository)

MINING SERVICES &

MINING SERVICES & SUPPLIES RETURN TO INDEX

Use Standard Flow Chart Symbols in Process approach Flowchart:

Start/End Process Flow Process Alternate Document Information/Data

Property of MES – Approved (Controlled document in Document Repository)

MINING SERVICES &

MINING SERVICES & SUPPLIES RETURN TO INDEX

Use Standard Flow Chart Symbols in Process approach Flowchart:

Start/End Process Flow Process Alternate Document Information/Data

Property of MES – Approved (Controlled document in Document Repository)

MINING SERVICES &

MINING SERVICES & SUPPLIES RETURN TO INDEX

Use Standard Flow Chart Symbols in Process approach Flowchart:

Start/End Process Flow Process Alternate Document Information/Data

Property of MES – Approved (Controlled document in Document Repository)

MINING SERVICES &

MINING SERVICES & SUPPLIES RETURN TO INDEX

EXCAVATION AND BACKFILLING

A) Materials used for backfilling:

Guidelines for Inspection of Backfill Material:

Sr. No Description Mode of Inspection Acceptance Criteria

Start/End Process Flow Process Alternate Document Information/Data

Property of MES – Approved (Controlled document in Document Repository)