WRD CSR 2022-23 (Specification)

GOVERNMENT OF MAHARASHTRA
WATER RESOURCES DEPARTMENT
COMMON SCHEDULE OF RATES

2022-23
SPECIFICATION
GOVERNMENT OF MAHARASHTRA
WATER RESOURCES DEPARTMENT
COMMON SCHEDULE OF RATES FOR 2022-23
DRAFT SPECIFICATIONS
INDEX
Pages
Sr.
Particulars
No.
From To
----- -----
1.0 SECTION-1
Lead Charges Statement for Materials

SECTION-2 1 56
2.0
Excavation & Embankment
SECTION-3 57 226
3.0
Concrete Work including Centering, UCR Masonry,
Brick Masonry & R.C.C. Pipes
SECTION-4 227 294
4.0
Tunnel Works
SECTION-5 295 382

5.0
Surveying & Investigation
SECTION-6 383 389

6.0
Hydrometeorology
SECTION-7 ------ ------
7.0 Valuation of Rehabilitation Works

SECTION-8 390 400
8.0 Flow Measuring Devices
SECTION-9 401 423

9.0
Marking Blue Line & Red Line
SECTION-10 424 448

10.0
Land Reclamation Work & Soil Survey
SECTION-11 449 501

11.0
Maintenance & Repairs
SECTION-12 502 968

12.0
Lift Irrigation Scheme & Pipe distribution network
INSTRUCTIONS
The standard specification shall be adopted for CSR 2022-23 of WRD, GoM. The specification is
grouped under following sections
Section No Name Of Section

Section 2 Excavation & Embankment
Section 3 Concrete Work including Cantering, UCR Masonry, Brick
Masonry & R.C.C. Pipes
Section 4 Tunnel Works
Section 5 Surveying & Investigation
Section 6 Hydrometeorology
Section 8 Flow Measuring Devices
Section 9 Marking Blue Line & Red Line
Section 10 Land Reclamation Work & Soil Survey

Section 11 Maintenance & repair including DRIP.
Section 12 Lift Irrigation Scheme & Pipe distribution network
Specifications of section 1 (Additional Lead Charges of all Materials Upto 500 Km & Lift
Charges) and section 7 (Valuation of rehabilitation work) are not required thus are not included.
The specifications under each section are distinguished by prefix mentioned against each. The reference
of specifications are incorporated in abstract under Colum no 3. The reference includes the no of the
particular section serial no of item and serial no of specification, thus ‘ Section 3,3’ will refer to item no
3 of section 3-
In most of the specifications for each item covers
1. General description
2. Scope
3. Material specification
4. Sequence of execution
5. Mode of measurement
6. Mode of payment
Indian standard and PWD manual have been adopted and referred to wherever necessary.
If additional specifications are to be added they may be drafted likewise
A) These specifications shall be thoroughly studied before deciding whether any addition to
standard specifications is required or some portion is to be modified due to new materials,
different processing, etc. such addition or modifications shall be included in the special
provisionsitems, in addition to the reference made to the standard specifications.
B) Where necessary, the specifications have been supplemented by sketches of clarity. The engineer
shall also supply detailed drawings where required. When, however, any discrepancy is found
between the drawing and the estimates or the specifications, the engineer’s decision as to which
shall be followed shall be final. “Engineer” shall mean the Executive Engineer in charge of the
work and shall include the superior Engineer Officers of the Engineering Department of the
Government of Maharashtra, i.e. the Superintending Engineer, Chief Engineer, etc.
C) Metric system has been adopted throughout these specifications for weights, measures, etc.
Rationalized metric standards have.
NOTE:- The specifications published for a common schedule of rate 2022-23 on the Water
Resources Department’s official website are general specifications. While working on the
tender procedure at the field level, detailed specifications are to be prepared as per
requirement and the actual nature of work.
Please refer note no.19 in “General note” in Abstract of Common Schedule Of Rate
2022-23.
For Office Use Only
Govt. of Maharashtra
Water Resources Department
SPECIFICATION FOR
EXCAVATION
2022-23
1
SECTION-2 : EXCAVATION
2.1 EXCAVATION IN SOFT AND HARD STRATA (ITEM NO. EW 1-EW 6)
2.1.1 DESCRIPTION OF ITEM:-

Excavation in soft and hard strata (by blasting and including secondary breaking) in
wet and dry conditions, including dressing, removing the surface boulders and
necessary excavation if required, depositing the material as directed, dewatering
including diversion with all leads and lifts etc. complete
2.1.2 SCOPE OF WORK

The item of excavation shall include furnishing all tools, plants, labour and material
required, providing quality assurance, providing any road or ramp required for
transportation of excavated material and their maintenance if any, line out of the profile
of excavation, setting out benchmark. Excavation in all types of strata met with (in dry
or wet condition) and to the designed section including controlled blasting wherever
required using delay detonators, providing and subsequently removing shoring and
strutting or cutting slopes etc., bailing out or pumping out water when separate
provision does not exist for it in the contract, sorting of the excavated material,
conveying and staking in stock piles clear beyond the work area for its use in
embankment with all lead and lift, disposal of surplus material in a manner as directed
by the Engineer-in- charge and preparing and testing of foundation. Maintaining the
excavation slopes and trenches, preparing the foundations as shown on the drawing and
as directed by the Engineer-in-charge, drainage and all operations covered within the
intent and purpose of this item of work.
Also the area of open excavation shall, where in the opinion of the Engineer-in-charge,
clearing is necessary be cleared of all trees, bush, rubbish and other objectionable
matter, and the material removed shall be burnt or other-wise disposed off as directed by
the Engineer-in-charge.
The scope of work shall also include deployment of experienced engineers and
necessary protection in view of safety, supply of facility for inspection and taking
measurements at any time, compensation for injury to life and damage to property if any
caused by the contractor's operation etc. The cost of all these items shall be deemed to
have been included in the unit rates of items contracted under excavation, at his own
cost etc. all complete.
2.1.3 QUALITY ASSURANCE

Quality Assurance is providing the confidence that an entity will fulfill the quality
requirements adequately by the ways of systematic quality planning and implementation
of quality assurance measures. The purpose of quality assurance is to foresee
bottlenecks and prevent them, identify and correct swiftly and suitably any problems
that might occur, and to uncover and eliminate the root cause of the same.
Contractor shall deploy quality assurance system on the work. It comprises the
2
deployment of experienced engineers in the field of works to be executed under the
agreement, the trained supporting staff for testing the construction material, test during
process & that on completed item as per requirement of Indian Standards for the item.
Contractor shall establish the field laboratory with all necessary survey & testing
equipment’s for field testing duly calibrated periodically
Contractor shall carryout periodical tests on material, process & finished end product.
The test report shall be analyzed as per prevailing relevant standards.
The monthly Quality Assurance report shall be prepared & submitted to Engineer in
Charge along with the information of work executed, material consumed & man,
machinery engaged for the work.
2.1.4 LINE OUT

The contractor shall establish at suitable points to the satisfaction of the Engineer-in-
charge permanent reference marks on the centre lines, as may be necessary and directed.
The permanent reference marks shall be inscribed on bronze pegs, set in substantial
concrete blocks where they will be free from any likely-hood of disturbance. Suitable
permanent bench marks shall be established. As the work progresses, centre line marks
shall be made on pegs, inserted at convenient interval to the satisfaction of the
Engineer-in-charge, for checking alignment, grades, levels etc. and also the dimensions
of the minimum excavation lines. The contractor shall, at all times, remain responsible
for the sufficiency and accuracy of all such bench marks and reference points.
All materials such as pegs, bamboos, strings, templates & survey equipments for
marking out slopes and labour required for line out shall be provided by the contractor
at his own cost and shall be responsible for their maintenance during the whole
construction period. The center line of excavation shall be clearly marked by pegs or
lime powder at 30 m. interval or at change in direction or at shorter intervals on curves,
in the beginning as directed by the Engineer-in-charge. The final line out shall be done
by fixing reference stone / concrete pedestal at suitable distances on either side of the
center line beyond the edge of dam, barrage, canal, canal structure and other structure or
any construction edges so that they are not disturbed during the construction period. The
position of these stones shall be marked on the foundation plan and drawings.
No change in the sanctioned plans and designs is permissible without the written
permission of Engineer-in charge.
The contractor shall layout and constructs one or more temporary or permanent bench
marks in some central place before start of the work, from which all important levels for
excavations shall be set. These shall be laid out with the prior approval of Engineer-in-
charge. No base line or benchmark or reference line shall be used without prior approval
of the Engineer-in-charge. The reference points and pillars already established by the
department in the work area shall be fully protected and maintained by the contractor.
He shall repair and rebuild the same in case of any damage.
The contractor shall provide all material and labour for establishing temporary or
permanent bench marks and for taking measurements of the work at his own cost. The
permanent bench marks shall consist of concrete / masonry pillar constructed with iron
3
plate connected to anchor rod and fixed in the pillar at the centre (with top of pillar &
plate flush) neatly plastered and leveled as per the directions of the Engineer-in-charge.
These permanent bench marks shall be properly established to ensure no settlements.
Benchmarks shall be well connected with grid system or any other bench mark
approved by the Engineer-in-charge. The bench mark shall be checked from adjoining
bench mark established or any other bench mark as will be directed by the Engineer-in-
charge at the start of every season. The bench marks shall be checked at the start of each
season.
After the line out is given, the original ground levels shall be taken in the presence of
Engineer-in-charge or his authorized representative before start of the excavation. All
levels shall be referred to an established bench mark not subjected to subsidence or
interference. The contractor shall have to sign the field books and plan showing the
working levels, longitudinal sections and cross sections of the portions of the alignment
that he has to tackle. The contractor has to submit signed field book and plans
showing working levels. If the contractor fails to submit them within three days, the
levels and sections recorded by the Engineer-in-charge will be final and binding on the
contractor and it will be treated that the site is handed over to the contractor by the
department, for all purpose mentioned in the contract.
Profile of designed canal reaches may be marked out at closer intervals of 10 m on

curves and 30 m in straight reaches or as decided by Engineer-In-charge. For dam, a
complete profile shall be set up at every 30 m length and at every change of section or
as decided by Engineer-In-charge. The contractor shall be responsible for the true and
proper setting out of the work in relation to original points, lines and levels of reference
and for correctness of the levels, dimensions and alignment of all parts of the work. If at
any time during progress of the work, any error appears or arises in the position of level,
dimension or alignment of part of the work, the contractor at his own expense shall
rectify such error to the satisfaction of the Engineer-in-charge. The checking of any line
or level by the Engineer-in-charge shall not in any way absolve the contractor of his
responsibilities.
2.1.5 ACCURACY OF ALIGNMENTS, GRADES, LEVELS ETC:

A few bench marks are fixed reference points, with the value of the levels and the co-
ordinates are fixed by the Government in the work areas. Plans showing the positions,
co-ordinates and level of the salient points will be supplied to the contractor on demand.
The contractor will fix his permanent points bench marks in relation to these. He shall
take all precautions to see that the points fixed by the Government are not disturbed by
his work and shall make good the damage, if any, at his own cost.
The contractor shall excavate true to alignment grade and level and shall check these at
frequent intervals as the work progresses. The contractor shall, provide, free of cost, all
facilities like labour, instrument etc. and all co-operation to the Engineer-in-charge to
check the alignment, grades, levels etc. whenever and every time they are asked for.
Such checking by the Engineer-in-charge shall not absolve the contractor from his
responsibility of maintaining the accuracy of the work. Any discrepancy or error
detected during the course of excavation or at the end of the work shall be set right by
the contractor at his own cost in a manner, satisfactory to the Engineer-in-charge
4
2.1.6 EXCAVATION
Work shall be executed as shown in the drawings and as directed by the Engineer-in-
charge. Edges shall be neatly aligned symmetrically to the center line. They shall be
done absolutely straight in straight reaches and smoothly curved on bends. Side slopes,
benching etc. shall be as directed by Engineer-in-charge. All the excavation surfaces of
backfill material against which concrete is to be placed shall be smooth and firm, true to
line and level. Suitable arrangements for drainage shall be provided to take surface
water clear off excavation during the progress of work.
2.1.7 CLASSFICATION
The classification of strata shall be as under.
1 Soft strata:
This shall include :
a) All excavation done in strata such as soil, silt, gravel, soft murum, stiff clay,
kankar and other similar material.
b) Hard murum:
This shall include all kinds of disintegrated rock or shale, indurated clay which can be
removed by means of pick or shovel.
c) Hard murum and boulder :
This shall include all kinds of disintegrated rock or shale or indurated sand or
conglomerate interspersed with boulders which do not need blasting and can be
removed with pick bar and shovel.
d) Soft rock :
This shall include all excavation in rock done without resorting to blasting and chiseling
and can be removed with a pick bar and shovel or excavator but which shall not come
under the category of Hard murum and boulders.
The boulders mentioned in above strata shall have a size measuring up to 0.5 m in any
dimension and up to 1 m in any other two dimensions.
At the change of strata, the contractor shall inform the department in writing before
preceding the work of excavation in hard strata. The Engineer-in-charge shall take the
levels of finished excavation in soft strata. The decision of the Engineer-in-charge shall
be final and binding on the contractor.
2 Hard strata:
This shall include all types of rock occurring in masses in all types of geological
formations which could best be removed by blasting or by splitting by mechanical or
chemical means where blasting is not permissible. It shall also include rock which
5
owing to the proximity of buildings, structures, electric line, and public roads or for any
other reasons has to be cut by means as directed by the Engineer-in-charge. It shall also
include boulders either embedded in mass or isolated ones, measuring over 0.50 m. in
any one direction and over 1 m in any other two directions which require blasting or
wedging and breaking for any removal. Merely the use of explosive in excavation shall
not be considered a reason for classification in hard strata unless regular blasting is
clearly necessary in the opinion of the Engineer-in-charge. The hardness of strata of
material to be excavated, presence of different types of geological constituents
requiring increased drilling efforts, consumption of explosives, labour and use of
machinery etc. shall not be considered as reason for claim or increase in contract rates.
In case of disputes over the classification of strata met with during execution, the
decision of the Engineer-in-charge shall be final and shall remain binding on the
contractor.
2.1.8 EXCAVATION IN ROCK

Excavation in rock shall be such that all sharp points of rock be chipped off so as not to
extend into the dam, barrage, canal, canal structure and other structure. Blasting in a
manner which is likely to produce overcuts which in the opinion of Engineer-in-charge
is excessive, shall not be permitted beyond pay line and no payment shall be made for
such excess excavation. Special care shall be taken to prevent overcuts or loosening of
materials on bottom and side slopes. The material excavated in a chain of 30 meters
shall be conveyed & stacked as directed by Engineer-in-charge.
The excavation shall be carried out according to the design with accurately graded bed
fall and side slopes as shown in the drawings and as directed by the Engineer-in-charge.
The cross section adopted in cutting is likely to change in side slopes according to the
depth and of different strata during actual excavation.
No claims for any variations in quantity of excavation resulting from deviation from the
instruction of the Engineer-in-Charge other than without the written instructions of the
Engineer-in-Charge would be accepted. To account for this, the central box cutting with
the canal bed width as it's width have to be taken to canal bed
level first, before the side slopes are tackled and treated. In portions where deep cutting
of more than 6 m is to be done, the mode of excavation to be followed must be
approved by the Engineer-in-charge before starting the work in such reaches and in any
case, width of excavation to be tackled initially shall not be more than bed width plus
depth. In no case, excavation shall be done by bore-blast of not more than 38 mm
diameter.
2.1.8.1 Removal of loose rock:

Before any excavation work is taken up, all loose rock, semi-detached rock in or close
to the areas to be excavated, which is liable to fall or otherwise endanger the workers on
the work shall be removed or stripped off. The methods employed shall be such that it
will not shatter or render unstable making unsafe any rock that was originally sound or
safe. Any material not requiring removal as contemplated herein but which may later
become loosened or unstable shall promptly and satisfactorily be removed. The cost of
such clearing shall be deemed to have been included in the unit rate under the different
6
item of excavation.
If the bottom of any excavation has been left exposed by the contractor and in the
opinion of the Engineer-in- charge,that has become badly affected by the atmosphere or
by water, then the contractor shall remove such portions of the deteriorated material as
directed.
2.1.9 BLASTING
2.1.9 BLASTING
2.1.9.1General
Blasting shall be carried out in a. manner that completes the excavation to the lines
indicated in drawings, with the least disturbance to adjacent material. It shall be done
onlywith the written permission of the Engineer. All the statutory laws, regulations, rules,
etc., pertaining to the acquisition, transport, storage, handling and use of explosives shall
be strictly followed.
The Contractor may any method or methods of blasting consistent with the safety and
job requirements. Prior to starting any phase - of the operation the Contractor shall provide
information describing- pertinent blasting procedures, dimensions and notes.
The magazine for the storage of explosives shall be built to the designs and specifications
of the Explosives Department concerned and located at the approved site. No unauthorized
person shall be admitted into the magazine which when not in use shall be 'kept securely
locked. No matches or inflammable material shall be allowed in the magazine. The magazine
shall have an effective lightning conductor. The following shall be hung in the lobby of
the magazine:
(a) A copy of the relevant rules regarding safe storage both in English and in the language with
which the workers concerned are familiar.( Act 1884, Explosive Rules 2008, The
Explosive (Amendment) Rules,2019 and as amended from time to time.)
(b) A statement of up-to-date stock in the magazine.
(c) A certificate showing the last date of testing of the lightning conductor.
(d) A notice that smoking is strictly prohibited.
All explosives shall be stored in a secure manner in compliance with all laws and ordinances,
and all such storage places shall be clearly marked. Where no local laws or ordinances
apply, storage shall be provided to the satisfaction of the Engineer and in general not
closer than 300 m from the road or from any building or camping area or place of human
occupancy. In addition to these, the Contractor shall also observe the following
instructions and any further additional instructions which may be given by the Engineer
and shall be responsible for damage to property and any accident which may occur to
workmen orthe public on account of any operations connected with the storage, handling
or use of explosives and blasting. The Engineer shall frequently check the Contractor’s
compliance with these precautions.
2.1.9.2 Materials, Tools and Equipment

All the materials, tools and equipment used for blasting operations shall be of approved
type. The Engineer may specify the type of explosives to be allowed in special cases. The
7
fuse to be used in wet locations shall be sufficiently water-resistant as to be unaffected
when immersed in water for 30 minutes. The rate of burning of the fuse shall be uniform
and definitely known to permit such a length being cut as will permit sufficient time to
the firer to reach safety -before explosion takes place. Detonator-s shall be capable of
giving effective blasting of the explosives. The blasting powder, explosives, detonators,
fuses, etc., shall be fresh and not damaged due to dampness, moisture or any other cause.
They shall be inspected before use and damaged articles shall be discarded totally and
removed from the site immediately.
2.1.9.3 Personnel
The blasting operation shall remain in the charge of competent and experienced supervisor
and workmen who are thoroughly acquainted with the details of handling explosives and
blasting operations.
2.1.9.4 Blasting Operations
The blasting shall be carried out during fixed hours of the day preferably during the mid-
day luncheon hour or at the close of the work as ordered in writing by the Engineer. The
hours shall be made known to the people in the vicinity. All the charges shall be prepared
by the man in charge only.
The Contractor shall notify each public utility company having structures in proximity to
the site of the work of his intention to use explosives. Such notice shall be given
sufficiently in advance to enable the companies to take such steps as they may deem
necessary to protect their property from injury. In advance of any blasting work within
50 m of an
railway track or structures, the Contractor shall notify the concerned Railway Authority
of the location, date, time and approximate duration of such blasting operations.
Red danger flags shall be displayed prominently in all directions during the blasting
operations. The flags shall be planted 200 m from the blasting site in all directions. People,
except those who actually light the fuse, shall be prohibited from entering this area, and
all persons including workmen shall be excluded from the flagged area at least 10 minutes
before the firing, at warning siren being sounded for the purpose.
The charge holes shall be drilled to required depths and at suitable places. Blasting should
be as light as possible consistent with thorough breakage of the material necessary for
economic loading and hauling. Any method of blasting which leads to overshooting shall
be discontinued.
When blasting is done with powder, the fuse cut to the required length shall be inserted
into the hole and the powder dropped in. The powder shall be gently tamped with copper
rods with rounded ends. The explosive powder shall then be covered with ramping
materialwhich shall be tamped lightly but firmly.
When blasting is done with dynamite and other high explosives, dynamite cartridges shall
be prepared by inserting the square cut -end of a fuse into the detonator and finishing it
with nippers at the open end, the detonator gently pushed into the primer leaving 1/3rd of
the copper tube exposed outside. The paper of the cartridge shall then be closed up and
securely bound with wire or twine. The primer shall be housed into the explosive.
Boreholes shall be of such size that the cartridge can easily go down. The holes shall
be cleared of all debris and explosive inserted. The space of about 200 mm above the
charge shall then be gently filled with dry clay, pressed home and the rest of the tamping
8
formed of anyconvenient material gently packed with a wooden rammer.
At a time, not more than 10 such charges will be prepared and fired. The man in charge
shall blow a siren in a recognized manner for cautioning the people. All the people shall
then be required to move to safe distances. The charges shall be lighted by the man-in-
charge only. The man-in-charge shall count the number of explosions. He shall satisfy
himself that all the charges have been exploded before allowing the workmen to go back
to the work site.
After blasting operations, the Contractor shall compact the loose residual material below
subgrade and replace the material removed below subgrade with suitable material.
2.1.9.5 Misfire
In case of misfire, the following procedure shall be observed:
(i) Sufficient time shall be allowed to account for the delayed blast. The man-in- charge shall
inspect all the charges and determine the missed charge.
(ii) If it is the blasting powder charge, it shall be completely flooded with water. A new hole
shall be drilled at about 450 mm from the old hole and fired. This should blast the old
charge. Should it not blast the old charge, the procedure shall be repeated till the old
charge is blasted.
(iii) In case of charges of gelignite, dynamite, etc., the man-in-charge shall gently remove the
tamping and the primer with the detonator. A fresh detonator and primer shall then be
used to blast the charge. Alternatively, the hole may be cleared of 300 mm of tamping
and the direction then ascertained by placing a stick in the hole. Another hole may then be
drilled 150 mm away and parallel to it. This hole shall then be charged and fired when the
misfired hole should _ explode at the same time. The man-in-charge shall at once report
to the Contractor’s office and the Engineer all
9
cases of misfire, the cause of the same and what steps were taken in connection
therewith.
lf a misfire has been found to be due to defective detonator or dynamite, the whole quantity
in the box from which defective article was taken must be sent to the authority directed
bythe Engineer for ` inspection to ascertain whether all the remaining materials in the box
arealso defective.
2.1.10 WORKING UNDER WET CONDITONS:

No distinction will be made as to whether the material excavated is dry, moist or wet.
Seepage water from springs or rainwater shall be suitably collected and drained away by
gravity, wherever it is possible to do so. Where, however, drainage by gravity is not
possible such water shall be pumped out, and paid for at the rates in the contract.
2.1.11 DISPOSAL OF EXCAVATED MATERIAL:

Suitable material out of the excavation, if approved or directed by the Engineer-in-
charge, shall be used in temporary works as for making platforms, for the stock piles
etc. Useful materials like rip-rap for pitching, rubble for masonry or for crushing should
be separated out and stacked as directed. The balance of the spoils, except that required
for the back filling, shall be removed, deposited and spread on the dump areas as shown
in the drawings or as directed by Engineer-in-charge in a neat and orderly manner
commencing from the farthest end and coming nearer to the faces of the tunnels / shafts.
No materials shall be dumped where it will spoil the aesthetics of the site or interfere
with accessibility of complete structures, nor shall any material be dumped where they
may be carried by flood waters and obstruct the natural course of the river. Dump areas
shall be levelled and trimmed to reasonably regular lines, all work shall be done with
reasonable neatness. Excavated materials shall not be carelessly thrown over the work
area but should be deposited directly in permanent positions, so far as consistent with
proper excavation of the work. The useful materials taken out as stated above, may be
used in masonry or concrete as the case may be, at contractor’s cost.
2.1.12 Storing and transport :
Explosives shall be stored in clean, dry, well ventilated magazines to be built for the
purpose by the contractor at his own cost. Fuses and detonators shall be stored in
separate magazines. Detonators and explosives shall be transported separately to the
blasting site.
Explosives shall be stored in a safe place at sufficient distance from the work and under
the special care of watchman so that in case of accidents, no damage occur to the other
part of the work. No objection certificate from the District Magistrate or Inspector of
Explosives shall be obtained as required by the Contractor. The contractor shall
purchase the explosives, fuses, detonators etc. only from a licensed dealer. Before
blasting activity is initiated by the contractor, the approval from Engineer-in-Charge is
necessary. The contractor shall be responsible for the safe transportation, storage and
custody as per the explosive rule and proper accounting of the explosive materials.
The Engineer-in-charge or his authorized representative has the right to check the
contractor’s store and account of explosives. The contractor shall provide necessary
facilities for this.
10
The contractor shall remain totally responsible for any damage arising out of accident
for workman, public or property due to storage, transportation and use of explosive
during blasting operation.
2.1.13 Restrictions of blasting :
a) Blasting which may disturb or endanger the stability, safety or the quality of the
foundation shall not be permitted.
b) Blasting within 30 meter of masonry or concrete work in progress or of a permanent
structure is shall not be permitted except special permission is taken from the Engineer-
in-Charge.
c) Progressive blasting shall be limited to two third of the total remaining depth of
excavation.
d) No large scale blasting operations shall be resorted to when the foundation excavation
reaches the last half meter. Only small charges may be allowed so as not to disturb the
foundation. However the excess excavation will have to be make good by M-20 grade
concrete at contractor's risk and cost.
2.1.14 Preparation of blasting :
Explosives shall be kept dry and away from the direct rays of the sun, naked lights,
steam pipes or heated metal etc. Only the quantity of explosives required for a
particular amount of firing to be done shall be brought to the site of work. All surplus
explosives left after filling the holes shall be removed at least 600 m. away from the
firing point.
A wooden stemming rod shall be used to push the cartridge into the shot-hole. Metal
rod or rammer shall not be permitted on the site of work. The charge shall be pressed
firmly into the place and not rammed or pounded.
The explosives shall be fired by means of an electric detonator placed inside a cartridge
and connected to the firing cable.
Due precautions shall be taken to keep the firing circuit insulated from the ground, bare
wires, rails, pipes or any other path of stray currents and to keep the lead wires short
circuited until ready to fire.
2.1.15 Drilling rock for blasting :
The holes for charging explosives shall be drilled with pneumatic drills, the drilling
pattern being so planned that rock pieces after blasting shall be suitable for handling
without any need for secondary blasting. The rock pieces so blasted shall be neatly
stacked at allotted places. Even after taking such precautions, if secondary blasting is
required, it shall be done at the cost of contractor.
2.1.16 Blasting operations :
Before any blasting is carried out, it shall be ensured that all workmen, vehicles and
equipments on the site are cleared from an area of 300 meters radius from the firing
point at least 15 minutes before the firing time by sounding a warning siren. The
blasting influence area shall be encircled by red flags.
All operations shall be carried out by the competent and experienced licensed
supervisors. The firing shall be conducted by a supervisor and the number of shots fired
at one time shall not exceed the permissible limits. In case of misfires, the unexploded
charges shall be carefully located after half an hour and shall be exploded by drilling a
fresh hole along side or the misfired hole (but not nearer than 600 mm from it) and by
11
exploding a new charge. The workmen shall not return to the site of firing until at least
half an hour after firing.
2.1.17 CONTROLLED BLASTING

Controlled blasting shall be got approved from the Chief Engineer prior to start with
any operation regarding it. Controlled Blasting with delay detonators achieves good
fragmentation with controlled throw, enabling easy mechanical handling and providing
control on ground vibration, noise and moving off rock chips / pieces.
Short delay series detonators are designed for use in opencast and underground mines,
for driving tunnels, shaft, sinking and in quarries where multi-shot rounds are required.
Long delay series detonators are designed for use in underground mining for driving
shafts and tunnels. When blasting is conducted in the neighborhood of roads, structures,
buildings or at any place which requires controlled blasting, only shallow shot holes
shall be drilled. The holes shall be filled with a light charge on explosive and the blast
controlled by placing steel plates loaded with gunny bags filled with sand or earth over
the hole and covering them with wire net fixed to the ground or any other suitable
method so as to ensure that the blasted material do not scatter. In such cases, short delay
detonators shall be used for blasting purpose.
The holes for blasting shall be drilled for a depth of only 40 cm thus increasing the
number of holes and correspondingly decreasing the charge required for each holes.
The holes as far as possible shall be slant. All the holes after charging shall be covered
by grill of steel rods which shall be suitably loaded by gunny bags filled with sand or
murum.
The steel grill shall be so lowered over the holes as not to cause any damages to the fuse
wire or charges and care shall be taken to see that the fuse wires remain free. The
loading shall be sufficient to prevent the overthrow of rock after blasting. In addition to
the above loading, the steel grill shall be securely anchored to the adjoining rock by
chain clamps. The steel grill shall extend at least 3 meters beyond the area to be blasted.
Contractor shall strictly adhere to the provisions of the prevailing explosive rules laws,
and local laws thereof etc. complete.
2.1.18 BREAKER
The excavation in hard rock through breaker shall include the machinery, operator and
fuel consumption. In restricted ways and in controlled conditions wherever it is not
possible to do controlled blasting and use breaker also, the excavation shall be done by
percussion needle attached to excavator or equivalent machine. All other specifications
are similar to controlled blasting.
2.1.19 PAY LINE

2.1.19.1 For canal
The minimum line is the line within which no unexcavated portion of any kind shall be
allowed to remain i.e. a neat profile line for unlined and underside of the lining proposed
if any for work of canal and disnet. All excavations shall be performed in accordance
with the lines, grades, levels and dimensions shown in the drawing or established by the
12
Engineer-in-charge. The dimensions shown in the drawing are tentative. During the
progress of the work, it may be found necessary or desirable to vary the slopes or the
dimensions of excavation from those specified in the drawings. The side slopes of
excavation shall be as steep as would stand with safety and as directed by the Engineer-
in-charge. If the slopes established are found to be steeper and likely to slide / slip, they
shall be made flatter by removing the additional material and introducing suitable berm
if possible and stable faces established as decided by the Engineer-in-charge.
Over-cut is defined as the excavation beyond pay line. Before taking up the execution
for canal, the contractor shall obtain following approved copies from the Engineer-in-
charge.
1. Canal alignment
2. Canal : CBL and cut off statement
3. Cross sections (with references of the benchmarks and field books.)
Canal section shall be excavated as shown on drawing or as directed by the Engineer-in-

charge. Both edges of the bank, specially the inner one shall be neatly aligned
symmetrically to the center line of canal. They shall be absolutely straight in straight
reaches and smoothly curved on bends.
Payment shall be made for the work done beyond the minimum excavation line as per
actual excavation or pay line whichever is minimum as prescribed in various strata and
side slopes as below.
i) For sides:
a) For sides, pay line shall be limited to 15 cm in average.

b) Provisions made in Government circular No.MIS-2015/(CR.No.253/15)/MP Dt.
01-09-2015 shall be followed till revised or new Government circular or Government
resolution will be applicable. Tolerance for over cut beyond pay lines arising out of
peculiar nature of rock at the site and other site conditions shall be decided by the
Engineer-in-charge of the work and his decision regarding over cuts shall be final.
Payment for excavation beyond pay lines up to tolerance in such specific cases shall be
made @ 40% 60% contract rate of the particular item of the work. However no payment
shall be made for excavation more than double the specified pay lines as mentioned
above beyond the minimum excavation line in any case. No tolerance shall however be
permitted in soft strata. Extra excavation beyond the designed section for sides in soft
strata shall be backfilled with murum as per standard specification and compacted to the
optimum dry density and optimum moisture content specified and at the contractor's
cost.
The classification of strata for pay line as decided by the Engineer-in-charge shall be
final and binding on the contractor.
ii) For bed:
Pay line in case of bed shall be
13
10 cm in average. In case of soft
strata, no pay line is admissible.
In case of hard strata, excavation beyond designed section shall be backfilled with chip
masonry in cement mortar 1:6.
2.1.19.2 Excavation for dam and other structures :

No payment shall be made for the work done beyond specified slopes of excavation.
Normally pay lines for different strata for excavation are defined as the lines starting
from the outer dimension of the masonry or concrete at foundation level and sloping up
as follows.
a) Soft Strata : 1:1
b) Hard strata : 0.25:1
c) Berms with Prior approval.
Notwithstanding the standards given above for slopes, the contractor shall take care to
see that the slopes are stable and no accident or slips would occur.
Any or all excavation carried out by the contractor beyond approved slopes for any
purpose or reasons shall unless ordered in writing by the Engineer-in-charge, be at the
expense of the contractor. The excess backfill due to slip or overcut excavation has to
be filled with the approved material as directed by the Engineer-in- charge and filling so
needed shall be carried out by the contractor as per the specifications of the
corresponding item of works at his own cost.
2.1.19.3 Overcut:
Overcut is defined as quantity of excavation beyond payment lines and the unit rate for
the volume payable within pay lines covers the cost of overcut unless otherwise
specified.
2.1.20 SORTING OF MATERIALS

Excavated material shall be sorted out as under.
2.1.20.1 Soft strata:
All the excavated material from the soft strata shall be carefully sorted out and used in
the respective zones in embankment for dam, barrage, canal, canal structures and any
other structure as per it's suitability and as directed by Engineer-in-charge. When
material from excavation is not utilised directly in respective zones, it shall be stacked
separately and neatly in a manner such that it shall be used in a particular zone only
according to its suitability. No intermixing of material of various zones is allowed while
utilising it in embankment. The excavated material which is not suitable for use in
embankment shall be immediately removed and deposited at such a place and in such a
manner as directed by the Engineer-in-charge.
2.1.20.2 Hard Strata:

Rubble and boulders from hard strata shall be sorted out and stacked in separate areas as
directed by the Engineer-in-charge. Stock Piles shall be of regular shapes allowing for
easy measurement. No stock piles shall measure more than 200 Sqm in plan and more
14
than 1.5 m. in height unless specifically permitted by the Engineer-in-charge in writing.
2.1.20.3 Conveyance of Material :

All the excavated material from excavation shall be selected properly by removing
bushes, roots, grass, other objectionable matter etc. and shall be sorted out into different
types of materials according to its suitability for use in different zones of embankment
as directed by Engineer-in-charge. The same shall be loaded in the vehicles proceeding
directly to the place of use except when such material is required to be stock piled.
2.1.21 STACKING AND DISPOSAL OF EXCAVATED MATERIAL

2.1.21.1 General :
The excavated material shall be stacked within the area approved by the Engineer-in-
charge. Disposal of all material from excavation shall be as per approved disposal plan
or instructions of Engineer-in-charge, regarding the location and deposition of the stock
piles, spoil banks or embankment. Before any excavation is started, the deposition of
soil shall be carefully planned so as not to obstruct normal traffic and traffic lines. The
material shall be dumped sufficiently clear off the edges of excavation so as not to
endanger stability of the slopes of the excavation and also to permit ample space for
lorry paths, installation and lifting of pumping devices, stacking construction materials
etc. Excavated stuff shall not be dumped near the outlet location. If the excavated
material is deposited in unauthorized land, such work shall not be measured for payment
unless suitable action as directed by the Engineer-in-charge is taken by the contractor.
In addition to non-payment of such work, suitable amount as directed by the Engineer-
in-charge shall be recovered from the contractor as deposited towards any extra cost
which Govt./Corporation may have to bear on account of the contractor’s unauthorized
action.
2.1.21.2 Stacking and utilizing useful material :

Useful material available from excavation which cannot be used directly shall be
stacked in separate area and with reference to the type of material. Stock piles shall be
as regular in shape as possible as directed by Engineer-in-charge allowing for easy
measurement. The material once stacked shall be utilised as and where required and as
directed by the Engineer-in-charge. The cost of the completed item of excavation shall
include the cost of re-handling of the material so stacked and reused.
2.1.21.3 Disposal of surplus material :

The excavated material which is not useful for use in embankment shall be stacked in
spoil banks with neatly made stable slopes as directed and properly trimmed, so as to
present a neat appearance or they may be deposited in other approved location.
Direct utilisation shall be done wherever contemplated in the same work otherwise,
lands for the spoil banks shall be demarcated. The quantity of excavated stuff and the
area required for dumping it shall be determined, prior to start of the excavation. The
area and location of spoil banks shall be got approved from the Engineer- in-charge. In
case of temporary stacking of excavated material before use in embankment work, the
same shall be stacked temporarily and arrangements for it shall be done by the
contractor at his own cost.
Care shall be taken that no natural drains get obstructed due to spoil banks or there shall
be diversion of naturaldrainage causing damages of other properties due to spoil banks.
15
In Case of dam, barrage and other structures:-
Spoils banks shall be formed beyond 50 m distance from the
edge of embankment. In case of canal and canal structures :-
It shall be deposited beyond the required total designed width for overall canal section.
A suitable berm shall be left between the toe of bank and edge of excavation as directed.
The spoil banks shall be so located that they shall not interfere with the natural flow of
river / nalla.
The excavated material shall not be carelessly thrown over the area of the work but shall
be deposited directly in permanent position consistent with proper execution of the
work. In partial banks, where a side embankment is required to retain water, it’s limit
shall be lined out before starting the excavation so that the soil may be disposed off
properly. All the material available from excavation shall be the property of
Government / Corporation and watch and ward of such material shall be exercised by
the contractor free of cost. All the surplus material shall be handed over to the
Government / Corporation after completion of the work. For any shortages in the
material, suitable recovery shall be effected from the final bill or security deposit of the
contractor. The material available from all excavation and remaining surplus after use
on the work from adjacent reaches of works etc. can be used by the contractor provided
the material is of designed criteria and used solely for the specific contract work and
prior approval of the Engineer-in-charge is taken.
2.1.22 SILTING OF EXCAVATION

2.1.22.1 Silting due to floods:
Government/Corporation not responsible:
If excavated pits get silted due to intervening floods, slips or any other cause till
completion of the work, the contractor shall excavate and restore the excavated pits and
section to the required shape and dimensions without any extra cost. Contractor shall so
plan that no flood shall damage the underground excavation or shall get silted.
2.1.23 BOX EXCAVATION

Initially, box excavation shall be carried out up to top of hard murum or in strata
wherever possible, thereafter stable slopes may be cut in soft strata as stated hereafter.
On striking hard strata in foundation trench, the surface of this strata shall be exposed
on all area of the trench and it shall be brought to the notice of the Engineer-in-charge
by the contractor who will record levels of the top of hard strata taken along
predetermined sections. Thereafter, further excavation in hard strata can be continued
up to foundation level to be fixed by the Engineer-in-charge. Failure to do so by the
contractor shall not entitle him to get payment for the work that may have been done
under item of hard strata.
2.1.24 PREPARING AND TESTING OF FOUNDATION

2.1.24.1 Scaling and trimming of foundations:
After rough excavation to the required depth is completed, scaling and trimming
16
operations for the removal of all pieces loosened during excavation or partly separated
from main rock mass by seams or cracks shall be carried out up to the satisfaction of the
Engineer-in-charge.
2.1.24.2 Treatment of weak local spots:

All weathered or partly or decomposed pieces of rock shall be removed so as not to
leave on the foundation any rock under than that is an integral part of the rock mass.
Areas of low bearing capacity, steep inclined seams, faults and crushed zone in an
otherwise good foundation, if permitted to be kept shall be cleared out to a sufficient
depth and refilled and plugged with masonry or concrete as directed by the Engineer-in-
charge.
2.1.24.3 Final finished surface of foundation:

The finally prepared foundation shall present a rough surface in cross section to give
added resistance to sliding. All smooth surfaces shall be roughened artificially to give a
good bond. The surface shall be free from steep angles and the edges of benches shall
be chamfered approximately to 450. Pinnacles of sharp projection shall be knocked off
and prominent knobs flattened.
2.1.24.4 Testing for soundness:

The finally finished foundation rock shall be tested by striking with a heavy hammer
and if loose portion of foundation rock is revealed by a hollow sound, it shall be
excavated further (without blasting) till a clear ringing sound is obtained.
2.1.25 CLEAN UP
On completion of the work specified in contract, the contractor shall clear away from
the job site as well as from private & public roads and surrounding areas, all rubbish,
debris and construction materials and contractor's tools, equipments and other property
before the work is finally accepted at his own cost.
2.1.26 THE RATE OF EXCAVATION WILL INCLUDE

The rate for the item will include as follows:-
a) Soft Strata:-
1) Furnishing all tools and plants, labour and material required for the work throughout
execution.
2) Providing quality assurance.
3) Line out of works, profiles etc. according to sanctioned plan or as directed by Engineer-
in-charge including setting up bench marks and other references.
4) Excavation to the designed section in dry or wet condition and removal of all materials
of whatever nature etc. including materials like explosives, removal of blows and slips
and use of tools, plants and equipments necessary for satisfactory completion of the
item and preparing bed for foundation.
5) Bailing and pumping out water when separate provision does not exists for it in the
contract.
6) Providing and subsequently removing shoring and strutting or cutting slopes except
when, separately provided for in the contract.
7) Sorting out of useful excavated materials, conveying them clear beyond the work area
and stacking them neatly, depositing for use in embankment in proper zone and disposal
17
of surplus material, preparing and testing foundation etc. with all lead & lift as directed
by the Engineer-in-charge.
8) Necessary protection to ensure safety and protection against risk or accident.
9) Supply of facilities for inspection and measurements at any time to the concerned
Government / Corporation.
10) Compensation for injury to life and damage to property if any, caused by
contractor’s operations connected with this work.
b) Hard Strata by blasting / controlled blasting :-
In addition to the points mentioned above which are applicable for excavation in soft
strata, the rate for this item shall include.
1) Drilling and blasting with delay detonators or wedging and breaking for any removal.
2) Loading the tipper and unloading the muck.
3) Marching away for next blasting and re-location after blasting.
4) Labour and staff required.
c) All applicable taxes, royalty and licensing fees etc.
2.1.27 EXECUTION PROCEDURE:

 For canal and structures excavation shall be tackled from head to tail. The
executed work shall be checked with the help of profile walls / furmas already
constructed.
 The excavation work must be checked at specified intervals and in
between the two cross-sections with the help of strings, so that there will not be any
outcrops / encroachment in the flow section.
 Classification of the excavation will be made from the cross sections visible at
the sides of excavation and from measurements of ridges which shall be left at 30 m. or
less as directed by the Engineer-in-charge, which must be removed immediately after
the final measurements have been taken except when orders are specially given to retain
these ridges. Where there is abrupt change in depth, additional cross sections may be
taken at the discretion of the Engineer-in-charge. No deadmen would be allowed. The
area shall be worked out from the cross sectional area by prizmoidal formula.
The contractor shall execute the earthwork and structures simultaneously so that entire
work gets completed simultaneously with quality.
2.1.28 MODE OF MEASUREMENTS

 The item will be measured on volume basis.
 All linear measurements shall be either horizontal or vertical for arriving at the quantity.
The measurement for the length and the width shall be recorded correct up to 10 mm,
limited, to those shown in the drawings or as directed by the Engineer and area
calculated up to two decimal places.
 The measurements shall be based on areas of cross-sections taken normal to the axis of
the structure or its part of the original ground surface and the surface of the finally
completed excavation within the pay lines, taken at every 10 meters along the axis of
structure or its part.
18
 Levels along the cross sections shall be taken at every 15 meters for dam and 5 meters
for structure as per necessity of work. Where there is abrupt change in depth, additional
cross sections may be taken at the discretion of the Engineer-in-charge.
 Quantities shall be computed by plotting the actual excavated levels and the original
ground or rock level and calculating the area between the original and the excavated
line from the cross sectional area by Prismoidal formula L/6*[ (A1+ A2)+(4AM)].
Where,
 L=length of the prismoid measured perpendicular to the two end parallel planes.
 A1=area of c/s of one end plane
 A2=area of c/s of other end plane
 AM=area of c/s of mid section plane
 The measurements of excavation shall be the measurements of cut as worked out from
the areas of cross sections of original ground and the finally excavated line i.e. within
the payable excavation lines.
 No payment shall be made for any silt, debris, etc. that might accumulate in excavation
pits during monsoons or summers, showers or otherwise on any account and the
removal there of shall be deemed to have been included in the contract rates for the
main items.
 Stack measurements- As a rule, measurement of the excavated material on stacks shall
not be permitted. However, in case of excavation in bouldery strata when it is not
possible to get a record of the excavated material in cross section, measurement of the
excavated material on stacks may be permitted by the Engineer-in-charge in writing.
 In such a case, the stacks shall be on level ground, rectangular in shape and shall not be
more than three meter in height.
 The deduction for voids in hard strata shall be made @ 40% of the measured stack
volume from the gross quantities of stack measurement to arrive at the net quantity.
The measurement shall be submitted by the contractor by way of superimposing
the executed work on the designed cross-sections which are prepared prior to the
start of the work at the prescribed intervals.
2.1.29 MODE OF PAYMENT

The payment for excavation items will be released in following stages.
Sr Percentage of full
Stage
No rateto be released
A) For dam and it's components and others
(I) Through Running Account Bill
i) For soft strata, when excavation is completed up to top of hard 90%

strata in a continuous reach of tackled length
ii) For hard strata, when excavation is completed in hard strata up to
designed foundation level in a continuous reach of tackled length.
90%
(II) Final Bill 100%
B) For Canal and structures
19
(I) Through Running Account Bill
i) When canal excavation is in soft strata
Excavation completed up to designed CBL & designed section in

a continuous reach of tackled length
90%
ii) When canal excavation is in hard strata
Excavation completed in hard strata up to designed CBL and designed

section in a continuous reach of tackled length
90%
II) After testing of canal 100%
Note:- The canal earth-work payment shall be released as below:
1. 25% after the 50% amount-wise work of structures is completed.
4. 90% after one rainy season amount-wise work of structures is completed.

5. 100% after canal flow test is successfully performed.
20
SECTION-2 : EMBANKMENT
2.2 EMBANKMENT (ITEM NO. EW 7-EW 19)

2.2.1 DESCRIPTION OF ITEM:-
Construction of embankment for hearting zone/ casing zone with selected material
directly from available/ already deposited spoil of excavation/ with selected material
from borrow area including conveying the material Spreading and laying in layers of
pre-defined depth, leveling the bank work, breaking clods, removing organic material,
including watering, mechanized compaction, including royalty of material with all leads
and lifts, etc. complete.
2.2.2 SCOPE OF WORK

The item of embankment shall include furnishing all tools, plants, labour and material
required, providing quality assurance, providing and maintaining quarry/ diversion road,
stripping of the borrow area, setting out and marking profile, excavating the material for
the case of approved borrow areas, preparing the ground for laying the embankment,
selection of material from the available material of excavation or from borrow area
(material shall satisfy all design and drawing requirements) and sorting out as per
approved design and drawing, conveying the material in dry or wet condition with all
lead and lift, placing in proper zone, laying in layers of specified thickness, leveling,
breaking clods, benching, providing necessary junction as per requirement, watering
and mechanised compaction to the specified standard proctor density and optimum
moisture content for each type of material and performing all necessary operations for
this activity and dressing the embankment to its final designed slope.
The scope of work shall also include finishing, maintenance and protection of
embankment, cleanup, carrying out quality control tests during execution and also
record tests and providing any assistance imparted for carrying out quality control test
etc.
2.2.3 QUALITY ASSURANCE

 Quality Assurance is providing the confidence that an entity will fulfill the quality
requirements adequately by the ways of systematic quality planning and implementation
of quality assurance measures. The purpose of quality assurance is to foresee
bottlenecks and prevent them, identify and correct swiftly and suitably any problems
that might occur, and to uncover and eliminate the root cause of the same.
 Contractor shall deploy quality assurance system on this work. It comprises,
A) the deployment of experienced engineers in the field of works to be executed under this
agreement,
B) the trained supporting staff for testing the construction material,
C) test during process & that on completed item as per requirement of Indian Standards for
the item.
21
D) Contractor shall establish the field laboratory with all necessary testing equipments &
experienced Lab
E) for field testing equipment shall be duly calibrated periodically.
F) Contractor shall carry out periodical tests on material, process & finished end product.
G) The test report shall be analyzed as per prevailing relevant standards.
H) The monthly Quality Assurance report shall be prepared & submitted to
Engineer in Charge along with the information of work executed, material
consumed & man, machinery engaged for the work.
2.2.4 BORROW PITS

2.2.4.1 General :
Material required for the construction of embankment shall be partly available from the
excavation of components of dam, barrage, canal structure and other structure.
Contractor has to sort the material so as not to allow boulders, shrubs or other such
organic and inorganic material which do not fit into the specification of embankment
material of hearting zone and casing zone. Cost of sorting out such material shall be
considered in the rate of corresponding item. No claim for payment shall be entertained
on this account.
It is likely that the speed of excavation and embankment may vary and material to be
made available from excavation may not be available at a time in anticipated quantities,
in such a cases contractor has to resort to material from borrow area to keep up work
progress. The contractor shall not claim for nonavailability of anticipated available
material for embankment work.
Additional material required for the construction of embankment or backfill

which are not available from the compulsory excavation from the components of
dam, barrage, canal, canal structure and other structures shall be obtained by the
contractor at his own cost which shall satisfy all requirements of the design of
bank.
The contractor is expected to have his own investigations carried out before tendering
for the work, for availability of material.
2.2.4.2 Prior approval to borrow area before start of the work :

All the material of approved quality (Proctor Density, Specific Gravity, Shear Strength,
Angle of friction, Coefficient of permeability) as per approved design and drawing
required for the construction of embankment shall be taken from the borrow pits.
Before any borrow area is opened, the material from the borrow area to be used for
particular zone shall be got approved from the Engineer-in-charge. The contractor shall
be responsible for all damages that may be caused to private property at any stage.
2.2.4..3 Location :
The borrow pits shall be as regular in shape having regard to the convenience of the
work during construction, its safety and appearance after its completion. Borrow pits
shall be so worked that the selected materials shall be furnished as required, as close as
practicable to the point of utilization.
Where borrow pits are opened adjacent to the dam, the edge of excavation shall not
22
approach the heel of the dam (U/s) closer than 100 m or ten times the maximum height
of the dam whichever is more. Where no positive cut off is provided, care shall be taken
that no pervious strata are uncovered by excavation borrow pits on the water side of the
dam, within a distance of ten times of the maximum height of the dam as measured
from the (U/s) heel of the dam and shall not be deeper than 2.5 m. In D/s side, any
excavation and construction shall not be allowed within a distance of 10 times the
maximum height of the dam from the toe of the dam or 200 m whichever is more.
In case of canal, no borrow pits shall be dug within 5m of the toe of embankment if
there depth is less than
0.50 m and within 10 m if their depth is more than 0.50m; or within such distance from
the toe of the bank where a 4:1 hydraulic gradient line cuts the ground surface,
whichever is more. Borrow pits shall not be more than one meter in depth and 25 m in
length. The bed of borrow pits shall be left reasonably smooth and even.
No charges will be paid for re-handling of available material. The borrow pits may be
given suitable side slopes to avoid undermining. All borrow pits shall be connected to
each other and these shall be connected to the nearest drainage channel so as to avoid
stagnation of water. The bottom of all pits shall be so fixed that the pit drains into some
natural course. The connecting drains shall be of suitable dimensions as directed by the
Engineer-in-charge.
No borrow area shall be taken on roads, village tracks, canal etc. No borrow pit shall be
allowed in the Government / Corporation land acquired for the canal, branches, minors
& sub-minors.
2.2.5 DIVERSION
The diversion if required shall be constructed to the satisfaction of the Engineer-in-
charge on the approved alignment as directed. Necessary sign boards reflectors shall be
displayed at start and entry of diversion at contractor's own cost.
2.2.6 EQUIPMENTS
All manual and mechanized modern & digitized equipments, shall be provided by the
contractor required for the construction of embankment since beginning till the end of
the work.
All tools & plants should be deployed in sufficient numbers. The contractor shall give
all facilities to the staff to conduct the optimum moisture content & dry density tests at
site at his own cost.
2.2.7 SETTING OUT AND MARKING PROFILE

Masonry or concrete pillar to serve as a benchmark shall be erected at a suitable point in
the area which shall be visible from the largest area. This benchmark shall be
constructed and connected to the GTS benchmark. Necessary profiles with strings
stretched on the pegs, bamboos, pillars etc shall be made to indicate the correct
formation levels before the work is started.
The contractor shall layout and construct one or more permanent benchmarks in some
central place before start of the work, from which all important levels shall be set.
23
permanent bench marks and for taking measurements at his own cost. These
benchmarks shall consist of concrete / masonry pillar constructed with iron plate
connected to anchor rod and fixed in the pillar at the centre (with top of pillar & plate
flush) neatly plastered and leveled as per the directions of the Engineer-in-charge. These
permanent benchmarks shall be properly established to ensure no settlements. Bench
marks shall be well connected with grid system or any other bench mark approved by
the Engineer-in-charge. The bench mark shall be checked at the start of each season.
The pegs, bamboos, pillars, boundaries and benchmark etc. shall be maintained by the
The contractor shall supply labour and material for constructing benchmark, setting out
and marking profiles etc.
For canal work, profile shall be set up at 60m apart over straight reaches and 15 m apart
at curves. In setting up the profile for an embankment, a suitable allowance shall be
made for settlement.
2.2.8 USE OF EXCAVATED MATERIALS

All the materials required for the construction of the appropriate zones of the dam,
barrage, canal, canal structure and other structure etc. shall come from following sources
in order of priority.
1) The materials obtained from the excavation of dam, barrage, canal, canal structure
and other structure etc. and approved for use in the embankment by the Engineer-in-
charge. The data of available material must have been used for deciding requirement for
design of section of dam or canal embankment.
2) After utilizing the materials obtained as above, the remaining materials required
for construction of embankment shall be taken from the approved borrow areas. The
materials so obtained from borrow area shall also be got approved prior to its use. In the
suitability of use of materials, decision of Engineer-in-charge will be final.
2.2.9 SELECTION OF MATERIALS

The embankment shall be constructed of material as approved by the Engineer-in-
charge and also laid as directed in the appropriate zones of the section as per design
requirement.
The borrow pit material or the material from excavation, shall be got classified from the
Engineer-in-Charge with regards to its suitability for the particular zone in the
embankment and shall be final and binding on the contractor.
Coefficient of permeability shall be
A) less than 10-4 cm/sec for Casing material &
B) that for hearting shall be less than 10-6 cm/sec.
C) If casing material is of impervious nature special filters must be provided in the design of
this section.
24
2.2.9A Cohesive Non-Swelling Soils (CNS):- Cohesive Non-Swelling Soils (CNS)
are soils possessing the property of cohesion of varying degree and non-expanding
type clay minerals such as illite and kaolinite or such other material and their
combination .
2.2.10 ZONING OF EMBANKMENT
For Dam and Canal:-
The material shall satisfy all approved design and drawing requirements. The material
shall also have specifications considered in designing various zones. It shall be free
from organic material. Also specifically, material used for various zones shall confirm
to the designed values of C, Ø, density, specific gravity, coefficient of permeability etc.
for respective zones.
2.2.11 COT filling and hearting zone :
COT filling and hearting zone shall be executed with selected impervious soil (Kp<10-6
cm/sec.).
Soil for COT filling and hearting zone shall be free from roots, grass, shrubs,
vegetation, trees, saplings etc. or other organic matter.
The soil to be used for hearting zone shall be from the available material of excavation
or from borrow area approved by the Engineer-in-charge.
However soils having high compressibility and higher liquid limit are not suitable for
this zone, as they are prone to swelling and formation of cracks.
Soils having organic contents are also not suitable.
All clods and lumps exceeding 5 cm in any direction shall be broken up as the work
proceeds.
2.2.11.1 Casing Zone :

Casing zone shall be of pervious soils (Kp<10-4cm/sec) and as per approved design and
drawing requirements.(Specific Gravity, Density, Shear parameters such as Angle of
friction(ø), Cohesion(C)) The relatively pervious materials which are not subjected to
cracking on direct exposure to atmosphere are suitable for casing zone.
Materials for casing zone shall be free from roots, grass, shrubs, vegetation mounds,
trees, saplings etc or other organic matter.
The material to be used for casing zone shall be from the available material of
excavation or from borrow area approved by the Engineer-in-Charge. All lumps and
clods exceeding 8 cm in any direction shall be broken up as the work proceeds. This
criteria of 8 cm clod shall not be applicable for rock fill dam.
2.2.11.2 Properties of material for hearting zone / casing zone :

Recommendations for suitability of soil used for earthen dam. (IS 8826)
Zoned section
Suitability Casing Hearting
Very suitable SW, GW GC
25
Suitable GM CL, CI
Characteristics of soil group pertaining to embankment (IS 1498)
Soil Group Symbol Typical name
GW Well graded gravel, gravel-sand mixtures with little or no fines.
SW Well graded sand, gravelly sand with little or no fines.
GM Silty gravels, gravel-sand-silt mixture
GC Clayey gravel, gravel-sand-clay mixture
CL Inorganic clay, gravelly clay, sandy clay, silty clay, lean clay of low
plasticity
CI Inorganic clay, gravelly clay, sandy clay, silty clay, lean clay of
medium plasticity
For Hearting, fine grained soil shall be such that more than 90% of soil passes 4.75 mm
IS sieve. Soil shall have coefficient of permeability less than 1x10-6 cm per sec.
For Casing, soil shall be grouped as shown below.
i) Fine grained soil:
Soil containing fraction not less than 90% passing 2.0 mm IS sieve.
ii) Medium grained soil :
Soil containing fraction not less than 90% passing 20 mm IS sieve.

iii) Coarse grained soil :
Soil containing fraction not less than 90% passing 40 mm IS sieve.
The designed drawing & specification shall clearly indicate the type of material
proposed to be used in different zones.
2.2.11.3 Random Zone :

Random zone if provided, shall consists of free draining mixture of rock fragments and
boulders. The material shall be so selected and dumped that the larger fragments shall
be placed near the outer slopes and the finer material adjacent to the inside slope of the
embankment. The fill shall be dense and well graded with no large voids and the surface
of the outer slope shall be fairly uniform with the same slope as shown on designed
drawings.
2.2.11.4 Stretches of Embankment :

The embankment shall be made minimum 150 meter in lengths and not in small stretches.
As far as possible, the embankment work shall be done in full length including gorge,
but if this is not possible due to some reason which is acceptable to Engineer-in-Charge,
the work shall be done as below.
26
Slopes in longitudinal direction should be such that there must be proper keying with
side embankments. Embankment shall be in progress with hearting, downstream filter
upstream casing and downstream casing sequentially.
2.2.12 SHRINKAGE/SETTLEMENT ALLOWANCE

The provision of shrinkage/settlement allowance, for embankment shall be made as under.
Extent of shrinkage / settlement allowance to be deducted :
2% of the height of the embankment of dam for dams and 5% of the height of
embankment of canal for canals. Methodology of providing shrinkage allowance :
The shrinkage allowance to be provided shall be calculated for various heights wherever
there is a berm or change of slope in the dam section and for the top of dam. The points
of berm width or change of slope and top width of dam shall be raised vertically by the
amount of shrinkage allowance to be provided for the embankment height at the
relevant point. The points so obtained shall be joined, starting from the original base
width.
2.2.13 EXECUTION OF EARTHEN DAM

2.2.13.1 Filling of Cut off Trench :
The trench shall not be filled until it has been passed by the competent authority.
The material to be used for filling the trench shall be the most retentive impervious soil.
It shall be free from vegetation, injurious salts etc.
Just before filling is commenced, the sides and bottom of the trench shall be roughened
by shallow longitudinal trenches or corrugations cut in the rock. Every effort shall be
made to secure a satisfactory surface of contact and good bonding between the rock
surface and the initial layer of the earth. Filling material shall be laid in layers of 23cm
thickness and thoroughly compacted by rammers and rollers so as to completely fill the
trench from side to side.
The filling shall be continued until the trench is completely filled and up to 0.6 m.
above ground surface, this upper part shall be constructed together with the
embankment on u/s and d/s side.
2.2.13.2 Construction of embankment :

2.2.13.2.1 Placing of materials :
The embankment shall be constructed to the lines and grades shown on the drawings.
The slopes of the division lines between zones or portions of embankment are tentative
and shall subject to variation at any time, prior to or during construction. The contractor
shall not be entitled to any additional allowance on this account. The contractor shall
maintain the embankment in an approved manner until the final completion and
acceptance of all the work under the contract. Care shall be taken to drain out all rain
water falling on the rolled surface away beyond the toe line of dam. The embankment
for each portion shall be maintained leveled. But if it is necessary to have slope, the
slope shall not be steeper than 1:20 (vertical to horizontal). All openings or gaps
27
through the embankment required for construction purpose shall be subjected to
approval and such openings or gaps if approved shall be constructed such that the slope
of the bonding surface between embankment in place and embankment to be placed is
not steeper than 1:4 (vertical to Horizontal). The suitability of each part of the
foundation for placing embankment materials thereon and of all materials for use in
embankment construction will be determined by the Engineer-in-Charge. The material
shall be placed in layers of specified thickness and compacted by mechanised
compaction method. If the rolled surface is very uneven containing hollows and humps,
the hollows shall be filled up and surface rolled before any fresh layer is taken.
2.2.13.2.2 Reference Point :

Before commencing the placement of embankment, all lines marking the extremities of
berm, hearting zone, casing zone, filter etc. of embankment shall be marked with
reference to reference pillars. The reference pillars shall be of concrete or masonry and
the information indicating chainages, levels, etc. shall be properly inscribed or written
on them as directed by the Engineer-in-charge. The contractor shall construct and
maintain all reference pillars. No extra payment will be admissible to the contractor on
this account.
2.2.13.2.3 Preparation of foundation and preparation of surface of earth work previously laid :
a) General :
No material shall be placed in any section of the dam until the foundation for that
section has been dewatered and suitably prepared and has been approved by the
Engineer-in-charge. It is necessary to ensure that the surface material of foundation
shall be as compact and well bonded with the first layer of the embankment as herein
after specified for subsequent layers of the earth fill. All portion of excavation made for
test pits or trial pits and all other existing cavities found within the area to be covered by
the dam embankment shall be filled with compacted earth fill in embankment and
payment therefore will be made as provided for hearting zone or casing zone in which
section the pits or cavities are filled.
b) Foundation other than rock :
The seat of the dam after it is stripped, shall be cleared of all loose or objectionable
material before placing any layer. The surface shall then be watered and rolled as
directed, if the surface material is not compact enough. The surface shall then be
scarified by ploughing or by harrows or by rake or by any suitable method, all clods
broken and then it shall be moistened to ±2% of the optimum moisture content.
c) Rock foundation :
Any steps or large depressions or humps caused by abrupt change in levels, shall be
evened out to the slope as decided by Engineer-in-charge or indicated on the approved
drawings. The removal of rock shall be paid under the item of excavation. If necessary,
the surface shall be roughened by shallow longitudinal trenches or corrugations cut in
the rock and the removal of rock shall be paid under the item of excavation. The rock
surface including all pockets or depressions shall be carefully cleaned off soil or rock
fragments before placing of the first layer. Dykes and seams of soft material shall be
opened out, cleaned to depth as directed and filled with selected impervious material or
28
lean concrete as directed by the Engineer-in-charge. The foundation surface shall be
moistened but no standing water shall be permitted when the first layer is placed. The
rock surface after moistening shall be given a slurry wash, and immediately after the
wash, (so as not allowing it to dry) first soil layer will be placed.
If exposed surface is very rough and uneven, so as to preclude the use of power
operated rollers and equipment, it shall be brought to an even surface by filling the
hollows and depressions in layers not more than 100 mm thick with moist well soaked
soil, having moisture content equal to ± 2% of optimum moisture content and
compacting the same by hand, pneumatic or mechanical tampers.
d) Earth work previously laid :
The treatment of the surface in this case before a fresh layer is placed will be the same
as for the foundation other than rock. Over compacted portions of embankment formed
due to constant traffic which are likely to separate from the layers below shall be
entirely removed without any extra cost.
e) Rock abutments or sides of rock cutting :
It shall be seen that no hollow sideways are left. Also all projections shall be trimmed
before placing embankment against rock abutments or sides or rock cutting, the same
shall be trimmed to 1/2:1 slope or preferably 1:1 slope and be thoroughly washed with
mud slurry and selected moist soil laid against the same until the mud wash is still wet.
The moist soil laid against rock surface shall be compacted by hand rammers or air
operated rammers. Soil with moisture content equal to O.M.C of dry weight of soil shall
be used for this portion.
f) The cost of operations involved in preparation of foundation surface shall be

included in the rates of embankment.
2.2.13.3 Laying and spreading in layers :

a) Approved material free from clods and lumps exceeding 5 cm. in any direction in
hearting zone and exceeding 8 cm. in any direction in casing zone shall be conveyed
directly from the source of excavation or from stock piles and laid in appropriate zones
of embankment and broken as the work proceeds as directed by the Engineer-in-charge.
The materials shall then be spread on the embankment in uniform and continuous layers
horizontally, unless earth work in slope has been permitted or specified.
b) The thickness of a layer shall be such that the desired density after compaction
shall be uniformly obtained throughout the depth. The thickness of the layer shall be 23
cm. loose and 15 cm. compacted by mechanised compaction method. The layers shall
be spread in uniform width and in stages to facilitate compaction by rollers. The work in
various zones shall as far as possible be raised simultaneously. However hearting layer
shall be kept higher only by one compacted layer than casing layer. If, any zone or its
part is permitted by the Engineer-in-charge to be raised higher than the part adjacent to
it, the loose un-compacted materials at the junction shall be removed as directed by
Engineer-in-charge. A minimum slope of 2:1 shall be provided at such junctions and
vertical difference between such two junctions shall not be more than 1.5 meters.
Rolling at the junction of two zones shall be done most carefully so as to blend the
29
two zones in each other in a satisfactory manner. The layer of earth shall have a
slight slope towards the centre. This will prevent the side slope from being washed
down. During monsoon, a small crown shall be maintained at the middle of
embankment work to facilitate easy drainage of rain water.
c) The distribution and gradation of materials throughout the impervious core

including the backfill of the cut off trench shall be free from lenses or pockets of
materials differing substantially in texture or gradation from surrounding material. The
excavation and placing operations shall be such that the material when compacted shall
be so blended as to secure the best practicable degree of compaction, impermeability and
stability.
d) If pebbles and rock fragments of size larger than permissible be found in approved
earth fill material, they shall be removed by the contractor either at the site of
excavation or after being transported in the earth fill but before the materials in the earth
fill are rolled and compacted. Such pebbles and rock fragments shall be placed in the
rock toe directly or disposed as approved and directed by the Engineer-in-charge.
e) In order that proper compaction can be done up to the edges of the designed
section, the section shall be widened by 30 cm on each side i.e. on upstream and
downstream side and extra material shall be deposited for this purpose at the section.
The whole section will then be compacted and then dressed and brought to the designed
slopes. Necessary extra quantity required to be handled for this purpose shall not be
paid for and is considered to be included in the rate of this item.
2.2.14 JUNCTION
2.2.14.1 Stability at Junction :
Junctions of earthwork with foundation, abutment, masonry, concrete structures and
outlets need special attention with reference to one or all of the following criteria.
a) Good bond between earthwork, masonry, concrete and foundation.

b) Protection of earth dam slope against scouring action, slip and
c) Easy movement of traffic.
2.2.14.2 Junction with spillway abutment :

The surface near abutments shall be suitably shaped and prepared to get good contact
between the impervious core of embankment and the rock. Overhang if any, shall be
removed. Vertical surfaces shall be excavated to form moderate slopes, not less than 1
in 4 to 1 in 5.
A wider impervious zone and smooth transitions are also provided sometimes at the
abutment contacts to increase the length of path of seepage and to protect against
erosion.
Sufficient creep length shall be provided between impervious section of the dam and
abutment, so as to provide safety against piping.
In this type of junction, the lateral abutment and retaining walls shall be provided to the
outer profile of earth dam. A monolithic key / core wall shall be provided perpendicular
to the rear face of abutment and extending into the earth dam portion, which will rest on
30
rocky strata.
2.2.14.3 Junction with Outlet :

Proper bond shall be provided between the earth work and the outer walls by providing
staunching rings at interval so as to increase the path of percolation along the contact as
per approved design and drawing.
2.2.14.4 Junction in embankment :

When joining new earth work to old, the old embankment must first be cut or benched
into steps with the treads sloping slightly towards the centre of the embankment. Old
work shall be wetted so that the new earth may adhere to old. Benches or slopes shall be
of suitable dimensions approved by the Engineer-in-charge. All benches or slopes shall
be got approved before new earthwork is keyed into them. No extra payment shall be
made on this account.
2.2.15 WATERING AND COMPACTION
2.2.15.1 Moisture content :

a) The water content of the earth fill material prior to and during compaction shall be
distributed uniformly throughout each layer of the material. The difference (W-Wo)
where W is the moisture content of the embankment being compacted and Wo is the
optimum moisture content as determined by the standard proctor compaction test,
expressed as percent of dry weight of soil shall be as follows.
i) (W-Wo) shall be ± 2% of O.M.C.
ii) The standard proctor compaction tests shall be taken by the department from time
to time. The equipment, labour and all other help etc. required to conduct such tests
shall be provided by the contractor. The material shall be brought to the proper water
content, by adding necessary amount of water or allowing moisture to evaporate either
at the borrow pit or on the dam before commencing compaction of layer. When water is
proposed to be added at the embankment, required amount of water to be sprinkled for
given quantity of soil shall first be calculated making due allowance for natural
moisture content. This calculated quantity of water shall then be thoroughly mixed with
the soil by means of the disc harrows or any other suitable method before compaction.
All charges for watering and mixing are included in the item of embankment.
b) It may be necessary to allow water to soak into the soil after sprinkling and
mixing, if necessary for sufficient time to have uniform moisture throughout the layer.
The contractor shall not get any extra payment for stoppage of work necessitated for
allowing soaking of the soil.
c) Water content of soil to be laid to fill hollows in rock foundation, and rock
abutments and near sides in rock cutting shall be as specified in this specifications for
"Preparation of foundation", to OMC ±2 percent of dry weight of soil. The same
moisture content shall be adhered to in case of filling at the sides of C.O.T. filling
around masonry or concrete structures.
31
2.2.15.2 Compaction :
All the material placed in the embankment shall have to be properly compacted to attain
a optimum dry density for the material under consideration.
The compaction shall be done uniform over the full width of the bank. The roller shall
be made to travel over the entire designed section of each layer so that the earth is fully
compacted. The surface of each layer of compacted material shall be roughened with a
harrow & thoroughly harrowed or raked before depositing the succeeding layer of
material and care shall be exercised to avoid the occurrence of seams.
Embankment shall be continuously executed from day to day. In case of break in

embankment work, the dried surface shall be well watered & harrowed before a fresh
layer of earth is laid on it. The spreading of the next layer shall be carried out only after
the whole underlying layer has been properly compacted.
The number of passes required per layer to attain the specified density shall be
determined by actual tests during initial stages of the work.
2.2.15.3 Tamping Compaction :
In the parts of the embankment inaccessible to the specified rolling equipment around
and in proximity of structures where rolling equipment shall not be permitted to operate,
compaction shall be accomplished either with manual or mechanical tampers of
approved type. Roller shall not be permitted and all fills within this distance shall be
tamped by manual or mechanical tampers.
All materials to be tamped shall be spread in layers not over 8 cm. thick when loose.
The O.M.C. and amount of tamping shall be such as to produce a degree of compaction
as specified. Special care shall be exercised to obtain a good contact and bond with
surface of concrete, masonry or other structures.
2.2.16 DRESSING OF EMBANKMENT

After completion of work, the embankment including spoil shall be dressed evenly to
the required section as directed with no extra cost to Government / Corporation. The
side slopes shall be accurately dressed to required slope & section by stretching string
between the template faces. Dressing shall be accompanied by watering and ramming,
including replacing or refilling the appropriate material.
The profile shall show the total height and slope including allowance for settlement.
The embankment shall be constructed evenly to the full section of the set out. The
finished embankment shall be dressed neatly to the section and slope shown by the
designed profile.
For canal, dressing and removal of inner side pride shall be done just before
commencing the lining as per direction of the Engineer-in-charge.
2.2.17 PROTECTION
Proper care shall be taken to ensure that the method of operation and compaction of the
embankment does not cause any damage or undue strain to any structural element.
Embankment over and around the structure shall be of approved quality material and
32
carefully placed and compacted.
The contractor shall take all precautions necessary for the protection of embankment by
diversion of streams, local surface drainage, rain water etc. likely to damage the
embankment. Any damage to the embankment due to no protection, inadequate
protection or by any other reason shall be made good by the contractor at his own cost.
2.2.18 FINISHING
The embankment shall be finished and dressed smooth and even in conformity with the
alignment, levels, cross sections and dimensions shown on the drawing with due
allowance for shrinkage. All damages caused by rain, floods or any other reason shall be
made good in the finishing operations at contractor's cost.
2.2.19 MAINTENANCE
The contractor shall be responsible for maintaining the bank work satisfactorily at his
own cost till finally accepted including making good any damages till defect liability
period.
2.2.20 TESTING
Field density tests shall be carried out to ascertain the state of compaction, which shall
be measured in terms ofdry density. Standard proctor density tests shall be carried out at
regular intervals to account for variations in the borrow area material.
Field Density test shall be conducted from time to time at site to ascertain whether
compaction is attained as specified. Per day, two tests of compacted earthwork per first
300 cum and then one test per every additional 300 cum shall be taken. Separate tests
are to be taken for the various zones of the dam.
In case, the tests show that the specified densities are not attained, suitable action shall
be taken either by moisture correction or by additional rolling, so as to obtain the
specified density, which shall be checked again by taking fresh tests at the same
locations. The test locations shall be so chosen as to represent the whole layer under
test. Each layer shall be tested for proper compaction before a fresh layer is allowed
over it.
All laboratory and field tests shall be carried out as per the standard procedure for a
particular test. Frequency of all tests shall be observed from time to time and maintained
according to quantity of work done.
2.2.21 ACCEPTANCE CRITERIA

The following criteria may be generally followed for compaction control.
i) a) Placement dry density (PDD)

≥ 95% in 98% of cases
Optimum dry density (ODD)
b) For remaining 2% of cases

PDD
33
≥ 90%
ODD
ii) a) Optimum dry density (ODD)

= 100% in 98% cases
Design dry density (DDD)
b) For remaining 2% of cases

PDD
≥ 90%
DDD
iii) Average value of

Placement dry density (PDD)
=100%
Optimum dry density (ODD)
The Soil shall be brought to ± 2% of optimum moisture content (OMC) as determined

in the laboratory by adding the required amount of water either at the borrow pits or on
the embankment.
CLEAN UP
On completion of the work specified in the tender, the contractor shall clear away from
the job site as well as from private & public roads and surrounding areas, all rubbish and
construction materials and contractor's tools, equipments and other property before the
work is finally accepted, at his own cost.
2.2.22 RECORD TEST

At the end of each season, record tests of the embankment shall be taken as per the
frequencies mentioned below.
Total earthwork Record Test Samples
1 below 0.50 (Mm3) 1 per 10,000 m3
2 0.50 Mm3 to 1.5 Mm3 1 per 15000 m3
3 1.5 Mm3 to 3.0 Mm3 1 per 20000 m3
4 Above 3.0 Mm3 1 per 40000 m3
 If the record test results are not found within norms, contractors shall rectify the work at
his own cost.
 75% dependable value shall satisfy the design requirement.
2.2.23 THE RATE OF EMBANKMENT WILL INCLUDE

The rate for the item shall include as follows :
 Furnishing all tools, plants, labour and material required for the work throughout
34
execution.
 Providing quality assurance.
 Providing and maintaining quarry road and diversions unless provided as a separate item in
the tender.
 Stripping of the borrow area.
 Setting out and marking benchmarks, profile and alignment etc.
 Preparing the ground for laying the embankment.
 Selection of the material from available material of excavation of dam component or
from borrow area including sorting out as per design and drawing for its use in suitable
zone.
 Conveying the material with all lead and lift, placing in proper zone, laying in layers of
specified thickness, leveling, breaking clods, benching, providing necessary junction
including watering and mechanised compaction to the specified standard / modified
proctor density and optimum moisture content for each type of material, dressing the
embankment to its final designed slope.
 Finishing the embankment.
 Maintenance and protection of the embankment.
 Carrying out quality control tests during execution and record test also.
 Clean up after work.
 Any assistance imparted for carrying out quality control test etc.
 All applicable taxes excluding royalty. (Royalty is reimbursable on producing valid
payment document.)
2.2.24 MODE OF MEASUREMENT

 It shall be the net quantity of embankment after deductions (e.g. Revetment, hearting
zone, inclined sand filter, sand mat, and rock-toe, etc.), if any.
 The quantity of item shall be computed by using prismoidal formula for which the
intervals thereof shall be decided by Engineer-in-charge wherever applicable as per site
conditions.
 The payment for formwork required for inclined sand filter, various drains if any, shall
be presumed to be included in the respective contract-rate.
 The Contractor shall submit the report covering all tests on material, testing of
embankment viz. density tests, sand tests, filter criteria tests, etc., field density tests at
required frequencies (i.e. tests during construction and prior to construction, and tests
after construction defined in relevant paragraphs.)
 It should also cover the analysis of the tests and the conclusion for the acceptance,
as per the relevant IS codes of practices.
 Measurement shall be recorded after satisfactory reports. The Engineer-in-Charge will
be responsible to verify and accept the report before accepting the measurements.
2.2.24.1 Preparation of foundation plan and relevant cross section :

Foundation plan with relevant cross sections of ground profile of dam seat of dam,
barrage, canal, canal structure and other structures showing dimensions and levels shall
be prepared by the Engineer-in-Charge and contractor jointly before commencement of
work.
2.2.24.2 For dam :

a) Filling cut off trench :
35
Quantity of filling cut off trench shall be computed on the basis of cross sections and
quantity worked out by prismoidal formula. The cross sections shall be taken at 15 m
interval or at closer distance as will be decided by the Engineer-in-charge and shall be
the same as the quantity of excavation paid for under the item of excavation of cut off
trench below stripped ground level. Any extra claims for filling of cut off trench due to
side slips caused due to negligence of contractor or resulting due to delay in filling of
cut off trench will not be paid for.
b) Embankment :
The work shall be measured on the basis of cross section and quantity worked out by
prismoidal formula. The cross section shall be taken at an interval of 15 meters or at
closer distance as will be decided by the Engineer- in-charge. The cross sections shall
indicate separate zones. The gross quantity of hearting, casing etc. as the case may be
shall be based on these cross sections indicating the separate zones of hearting, casing,
filler material, rock fill etc. to arrive at the correct quantity of hearting zone and casing
zone that went into embankment.
2.2.24.3 For Canal:

The measurements of embankment of canal on both inspection path and service road
side shall be recorded on cross-section basis taken at 15 m or closer distance as decided
by the Engineer-in-charge and quantity executed in hearting zone and casing zone
section shall be worked out separately.
All usable quantities shall be paid under corresponding items. Quantity of utilizable
spoils in hearting zone and casing zone section shall be deducted from total embankment
work in hearting and casing section respectively. The balance quantities shall be paid
under embankment from borrow area. The benching and preparing ground for
foundation will not be paid separately.
2.2.24.4 Shrinkage Allowance :
Extent of shrinkage / settlement allowance to be deducted :
2% of the height of the dam for dams and 5% of the height of canal embankment for
canals.
2.2.24.5 Mode of Measurements:

 The item will be measured on volume basis and will be in cubic meter.
 It shall be the net quantity of embankment after deductions (e.g. Revetment, hearting
zone, inclined sand filter, sand mat, and rock-toe, etc.), if any.
 All linear measurements shall be either horizontal or vertical for arriving at the quantity.
The measurement for the length and the width shall be recorded correct up to 10 mm,
limited, to those shown in the drawings or as directed by the Engineer and area
calculated up to two decimal places.
 The measurements shall be based on areas of cross-sections taken normal to the axis of
the structure or its part of the original ground surface and the surface of the finally
completed embankment within the pay lines, taken at every 10 to 15 meters along the
axis of structure or its part.
 Levels along the cross sections shall be taken at every 15 meters for dam and 5 meters
36
for structure as per necessity of work or as decided by Engineer-In-charge. Where there
is abrupt change in height additional cross sections may be taken at the discretion of the
Engineer-in-charge.
 Quantities shall be computed by plotting the actual bank work levels and plotting it on
designed cross section with original accepted ground or rock levels and calculating the
area between the original and the excavated line from the cross sectional area by
prismoidal formula L/6*[(A1+ A2)+(4AM)]. Where,
 L=length of the prismoid measured perpendicular to the two end parallel planes.
 A1=area of c/s of one end plane
 A2=area of c/s of other end plane
 AM=area of c/s of mid section plane
 The payment for formwork required for inclined sand filter, various drains if any, shall
be presumed to be included in the respective contract rate.
 The Contractor shall submit the Quality Assurance Report as per Para 2.2
(Page no. Em-1) covering all tests on material, field tests, (Soil, stone, aggregates, sand
tests, filter criteria etc.), at required frequencies (i.e. The tests of materials, tests during
construction and tests final placement defined in relevant paragraphs.)
It should also cover the analysis of the tests and the conclusion for the acceptance, as
per the relevant IS codes of practices.
Measurement shall be recorded after satisfactory reports.

 The Engineer-in-Charge will be responsible to verify and accept the report before
accepting the measurements.
 The measurements shall be recorded on cross section basis.
 Final measurements can be taken only after one rainy season is passed.
 The measurements shall be based on the accepted foundation plan, relevant cross
sections and the completed section of the dam at the time of taking cross sectional
measurements.

Payment shall be done on the basis of cubic meter.
Sr. Percentage of
Stage
No. full rate to be
released
A) Through Running Account Bill
1) For Dam
a) Embankment satisfying all quality assurance and quality control

tests
90%
2) For Canal
a) Completion of canal embankment satisfying all quality assurance

and quality control tests, provided bank work shall be in continuous
reach.
(If work is in discontinuous reach only after written permission 90%
37
byEngineer in Charge, then payment will be at 60%)
Through Final Bill

B)
(Along with Record Drawings, Quality Assurance reports as per Para
2.2, Page No. Em-1) 100%
2.2.26 REGISTERS TO BE MAINTAINED
2 Sand (A)
Sample Signature with name &

Sr. No Date Time Location Silt % Bulkage Designation
Maintained by Checked by
/Type
1 2 3 4 5 7 8
38
2 Sand (B)
Signature with name

Sieve Analysis
Sieve &Designation
Sr. Date Location
Analysis
No. /Type I.S. Wt. % age Cumulat - FM
Size retain wt i ve. % As per I.S. 383 - 1970-T-4/P-11 Std Maintained Checked
in ed retaine Weight passing %age passing for sand grading zone by by
mm i d Retaine
ngm d
1 2 3 4 5 6 7 8 9 10 11 12 13 15 16
I II III IV
90 - 95 -
4.75 90 - 100 90 - 100 100 100
85 - 95 -
2.36 60 - 95 75 -100 100 100
75 - 90 -
1.18 30 - 70 55 - 90 100 100
80 -
600 15 - 34 35 - 59 60 - 79 100
300 5 - 20 8 - 30 12 - 40 15 - 50
150 0 - 10 0 - 10 0 - 10 0 - 10
75 For crushed sand limit increased to 20%

The total amount of grading outside the
-75 limit
Total
39
3 Coarse aggregate A
Signature with name

Sieve Analysis As per Mix Design
Sr. Date MS Location &Designation
No. A
40 20 10 4.75 40 20 10 4.75 Maintained by Checked By
1 2 3 4 5 6 7 8 9 10 11 12 13 14
3 Coarse aggregate B
Signature with name &

Flakiness Abrasion Impact Crushing Alkali Designation
Sr. No Date Locations index value test value value test Aggregate
Maintained Checked
test
by by
1 2 3 4 5 6 7 8 9 10
40
7 Stone
Sample Signature with name

Quarry Water Specific Crushing Lab &Designation
Sr. No Date Identification/
Component Source Absorption Gravity Strength Ref.
Location
1 2 3 4 5 6 7 8 9 10
9 Field Density Test Earth Work
DDD = Signature with name &

Sample Location PMC NMC PDD ODD Designation
Date PDD/ODD
Sr. No. & Quarry
Location Maintained Checked
Time Chainage Offset R.L
by by
1 2 3 4 5 6 7 8 9 10 11 12 13
41
10 Field Register for Proctor Density (P.D.) Test
Sample Signature with name

Sr. No Date Source Quarry O.D.D OM &Designation
Identification Location . C
No Maintained by Checked by
1 2 3 4 5 6 7 8 9
11 Relative Density
Method of construction / formwork is used or specify the work method
Weight of Weight of
Weight of
Location Sample Location Sand Sand Weight
Date & Weight of wet soil
Sr. No. of of sand
Time sand in pit (Sand) from
Quarry Ch. Offset R.L. +Cylinder +Cylinder in cone
pit
before after
pouring pouring
1 2 3 4 5 6 7 8 9 10 11
42
2.3 PITCHING : (ITEM NO. EW 20A,EW 21,EW 22)
2.3.1 SCOPE- The item shall consist of furnishing of all tools, equipment, contractor’s own
material and labour required for quarrying, transporting and laying the pitching
including bedding, dressing of embankment to design slopes and other operations
necessary and ancillary there to with all leads and lifts etc. completed.
2.3.2 MATERIALS
(a) Sand – The sand layer shall be 150 mm thick or as decided by Engineer-In-charge.
The sand shall be from hard, dense and durable rock formations. The maximum
percentage of materials less than 0.074 mm size shall be 5% by weight and it should not
contain organic materials. The maximum size of particle shall be 6 mm (1/4 inch.) The
specific gravity of particles shall be not less than 2.60. The sand shall be well graded
and it should satisfy the filter criteria with the adjoining filter and base materials. If
necessary the sand may have to be washed or screened without any extra cost. The sand
is to be supplied by the contractor from approved quarries, and the intern includes all
charges of supply and rehandling includes collecting, screening, transporting, washing,
stacking etc. with all leads and lifts involved for supply of sand.
(b) Metal - The metal shall confirm to the specifications given under the sections of
filter materials. In addition the metal shall be well graded 0 1.5 mm size to 40 mm
maximum size.
If natural gravel deposits satisfying filter criteria are not available, the use of metal shall
be permitted as filter material. The maximum size permissible shall be 40mm. Metal
shall consist of broken crushed rock, having clean, hard, durable, dense rock pieces. It
shall be reasonably well graded with sizes as shown on the drawing subject to clause (d)
below. The percentage of materials below 0.074mm. size shall be less than 1%. The
item includes breaking, screening, transporting, stacking etc. with all leads and lifts
involved for supply of metal. The size of the metal as shown on the drawings are
tentative and subject to the change as required to satisfy criteria with adjacent materials.
(c) Rubble for Pitching: The layer of rubble for pitching shall be 300 mm or 450 mm
as per the contract. Stones for pitching shall be of sound, hard, dense and durable rock
and should not break down or disintegrate on long exposure to water and air. The rubble
shall be got approved from the Engineer - in - charge
Size - The rock fragment shall be reasonably well graded containing at least 60 percent
of stone weighing 30 kg, or more. Minimum size shall be weighing 10 kg.
(d) 1.The materials for filling the drains of drainage mats or slant drains, shall consist
of sand, gravel and crushed metal suitably graded to satisfy the filter criteria. The
coefficient of permeability of draining materials should be more than 6 times that of
base materials.
2. Following criteria should be satisfied by the well graded sand to be
used the filter i)Co-efficient of uniformity
43
D60/ D10 >4
ii)Co-efficient of
curvature
(D30)2/ D60 x D10 >4
It should also satisfy the following filter criteria with the base material immediately in
contact with.
i) D 15(Sand)/ D 85(Base Material) <5
ii) D15 (filter material) / D15 (base material) > 4 and <20
iii) D 50 (Sand) / D 50 (Base Material) <25
iv) Gradation curve of sand should be roughly parallel to that of base material.
The size of the materials shown on the drawings are tentative and may require
modifications if they are not found to satisfy filter criteria The contractor shall be bound
to carry out such modifications as directed by the Engineer-in-charge, without any extra
cost
(e) Quarries: The rubble quarries and rock stacks from compulsory excavation shall
be got approved from the engineer in charge. Approval to quarry and stacks shall not be
to mean that all rubble available from that quarry is also approved by the engineer in
charge and only approved quality of rubble will have to be used.
2.3.3 LAYING
(a) The bed slope shall first be prepared to receive the pitching and the rubble
pitching shall be laid on filter backing consisting of 15 cm. Metal base on the earth
slope and 15 cm. quarry spalls on the metal base. The thickness of the rubble pitching
shall be 300 mm or 450 mm. This thickness of rubble pitching is exclusive of the
thickness of filter backing of metal and quarry spalls.
(b) The material for filter base shall be laid by spreading without segregation in
uniform layers of specified thickness to the lines and grades of the embankment.
(c) Laying of Rubble Pitching --Stones shall be placed on end with the broadest side
down and length normal to the slopes. Larger rock fragments should be uniformly
distributed with smaller rock fragments filling the spacing between the larger fragments
in such a manner as will result in compact uniform layers of pitching. The pitching
could be made in two layers but stones in each layer should be as large as possible and
the stones in top layer should be made to interlock with the bottom layer.
The interstices between larger stones shall be filled with chips of as large size as
possible properly hammered in. Such filling shall be carried out simultaneously with
44
placing in position of the larger stones and shall in no case be permitted to fall behind.
The wedging shall be so done thatto chip can be removed by hand. No loose spalls or
chips should be laid on the top surface of the pitching. The chips shall not be used as a
substitute for full thickness of large stones. The surface should present reasonably
uniform slopes as designed with a dense but rough face. The guide wall shall form part
of the pitching.
2.3.4 MODE OF MEASUREMENTS.

(1) The item shall be measured in sqm. The measurements shall be separately taken
(a) for filter baseand (b) for stone pitching and paid for separately.
(2) Measurements shall be of the total volume of pitching or filter base to the required
thickness laid on the area as directed. No deductions for voids will be made. The rates
are inclusive of all leads and lifts.

Payment shall be done on the basis of square meter.
Sr. Percentage of full

Stage
No. rate to be released
1) For Dam

tests
90%
2) For Canal
a) Completion of canal embankment satisfying all quality assurance

and quality control tests, provided bank work shall be in continuous
reach.
(If work is in discontinuous reach only after written permission 90%

byEngineer in Charge, then payment will be at 60%)
Through Final Bill
B)
(Along with Record Drawings, Quality Assurance reports as per Para
2.2, Page No. Em-1) 100%
45
2.4 PROVIDING AND LAYING OF QUARRY SPALLS (ITEM NO. EW 20B)
2.4.1 SCOPE- The item shall consist of furnishing of all tools, equipment, material and labour
required for quarrying, transporting and laying the quarry spalls including bedding,
dressing of embankment to design slopes and other operations necessary and ancillary
thereto.
2.4.2 MATERIALS.
(a) Quarry Spalls- The quarry spauls shall consist of clean, hard, durable, dense rock
fragments of sizes varying from 50 mm to 150 mm. Material below 0.074 mm size
shall be less than 1 per cent. The item supply of quarry spalls includes all charges of
supply rehandling, breaking bigger pieces, transporting, stacking etc. with all leads and
lifts.
(b) Quarries : The quarries and quarry spalls stacks from compulsory excavation
shall be got approved from the engineer in charge. Approval to quarry and stacks shall
not be to mean that all rubble available from that quarry is also approved by the
engineer in charge and only approved quality of quarry spalls will have to be used.
2.4.3 LAYING - a) The quarry spalls of 15 cm shall be laid on metal base which is laid on
earth slope.
Measurements shall be on sq. meter basis .No deductions for voids will be made.
Payment shall be done on the basis of sq. meter.

Stage
1) For Dam

tests
90%
Through Final Bill

B)
(Along with Record Drawings, Quality Assurance reports as per
Para 2.2, Page No. Em-1) 100%
46
2.5 ROCK TOE (ITEM NO.EW 23)
2.5.1 SCOPE-The item shall consist of furnishing of all tools, equipment’s,

materials and labour required for providing and laying rock toe including foundation
cleaning and including hand packing and adjusting the sides to correct slopes and
performing all operations necessary and ancillary there to.
2.5.2 MATERIALS:
(a) The Rock Toe shall consists of suitable free draining mixture of rubble, rock fragments,
boulders and cobbles from the compulsory excavation or quarries as the case may be.
The material will be fairly well graded consisting of principally of rock fragments
ranging in weight from 10 kg to 100 kg, but with sufficient fine materials, about 10 per
cent such as rock spauls cobbles and gravel to fill the voids among the larger particles.
However, the materials should not contain silt, clay and sand more than 1 per cent.
The rock fragments shall be of hard, dense,durable sound rock and shall not contain any
friable or soft materials. The rubble shall be conveyed for rock toe only after approval
by engineer-in-charge.
(b) Quarry Spalls- The quarry spauls shall consist of clean, hard, durable, dense rock
supply rehandling, breaking bigger pieces, transporting, stacking etc. with 1 km leads
and all lifts.
(c) Quarries : The quarries and quarry spalls stacks from compulsory excavation shall be
got approved from the engineer in charge. Approval to quarry and stacks shall not be to
mean that all rubble available from that quarry is also approved by the engineer in
charge and only approved quality of quarry spalls will have to be used.
(d) Metal - The metal shall confirm to the specifications given under the sections of filter
materials. In addition the metal shall be well graded 1.5 mm size to 40 mm maximum
size.
47
If natural gravel deposits satisfying filter criteria are not available, the use of metal
shall be permitted as filter material. The maximum size permissible shall be 40mm.
Metal shall consist of broken crushed rock, having clean, hard, durable, dense rock
pieces. It shall be reasonably well graded with sizes as shown on the drawing subject to
clause (d) below. The percentage of materials below 0.074mm. size shall be less than
1%. The item includes breaking, screening, transporting, stacking etc. with all leads
and lifts involved for supply of metal. The size of the metal as shown on the drawings
are tentative and subject to the change as required to satisfy criteria with adjacent
materials.
(e) Sand – The sand layer shall be 150 mm thick or as decided by Engineer-In-charge. The
sand shall be from hard, dense and durable rock formations. The maximum percentage
of materials less than 0.074 mm size shall be 5% by weight and it should not contain
organic materials. The maximum size of particle shall be 6 mm (1/4 inch.) The specific
gravity of particles shall be not less than 2.60. The sand shall be well graded and it
should satisfy the filter criteria with the adjoining filter and base materials. If necessary
the sand may have to be washed or screened without any extra cost. The sand is to be
supplied by the contractor from approved quarries, and the intern includes all charges
of supply and rehandling includes collecting, screening, transporting, washing, stacking
etc. with all leads and lifts involved for supply of sand.
2.5.3 QUARRIES - In case of materials from quarries the rubble quarries shall be
got approved from the Engineer - in - charge. Approval to the quarries shall not be taken
to mean that all the rubble available from the quarry is also approved. The rubble shall
be conveyed only after it is approved by engineer in charge. Soft rock or friable rock or
dust or any unsuitable material should be discarded in quarry only.
Rubble required for the construction of Rock-toe shall be contractor's own or is

available in total quantity from the excavation of cut-off trench and spillway excavation
Contractor has to sort the material so as to obtain sound quarried rubble. The contractor
may be required to carry out secondary blasting to obtain the rubble in required size and
shape. Cost for sorting necessary secondary blasting and transporting is already
considered in the rate of corresponding item. No claim or payment shall be entertained
for this.
In case of contractor's own material from quarries, the rubble quarry on shall be got
approved from the Engineer-in-charge. Approval to the quarries shall not be taken that
all the rubble available from the quarry is also approved. The rubble shall be conveyed
only after it is approved by the Engineer- in-charge. Soft rock or friable rock or any
uncountable materials should be discarded for which no payment will be made to the
contractor.
The materials shall be so selected and dumped that as far as practicable the larger
fragments shall be placed near the outer slopes and the finer materials adjacent to the
inside slope of the rock fill zone. The will shall be done and will be graded with no large
void or cavities and surfaces of the outer slopes shall be fairly uniform with
approximately the same slope shown on the drawings or as directed. The work should
present a dense rough surface or well keyed rock fragments. The rock fill shall be
placed in approximately horizontal layers of about 0.5 m. thickness. The stones shall
be hand packed to as to tightly and neatly wedge the rock fragments together. Stones of
48
smaller size will be laid next to the filter materials. The filter materials adjacent to the
rock fill shall be laid simultaneously in regular layers to the designed slopes and width.
2.5.4 LAYING Foundation.-a) The foundation to the rock toe shall be either rock
or a compact incompressible soft strata. In case of soft strata filter or transition zone will
be provided as directed and paid under the item of filter material. Rock toe will not be
laid on any foundation that is which the rock fragment will punch in by pressure. All
loose material shall be removed before laying the rock fill.
(b) Placing: --The materials shall be so selected and dumped that in so far as
practicable, the larger fragments shall be placed near the outer slopes and the finer
material adjacent to the inside slope of the rock till zone. The fill shall be dense and
well graded with no large voids or cavities and surface of the cutter slope shall be fairly
uniform with approximately the same slope shown on the drawings or as directed the
work should present a dense rough surface of well keyed rock fragments. The rock fill
shall be placed in approximately horizontal layers of about 0.5 m. thickness. The stones
shall be hand packed to as tightly and neatly wedge the rock fragments together. Stones
of smaller install be laid next to the filter materials. The filter materials adjacent to the
rock fill shall be laid simultaneously in regular layers to the designed slopes and widths.
2.5.5 MODE OF MEASUREMENTS - Measurements shall be of the gross

volume of rock toe placed without any deduction of voids. The volume shall computed
by trapezoidal formula by the cross sections taken at every 10 meter intervals or at
closer as decided by Engineer-In-charge. No work beyond the slopes shown in the
drawings shall be paid unless directed in writing by the Engineer - in – charge
No work, beyond the slopes shown in the drawings shall be paid for, unless directed in
writing by theEngineer-in-charge.
The contract rate shall be for one cum. of rubble, sand, quarry spall and graded gravel
each laid as per designed section.


Stage
1) For Dam
a) Embankment satisfying all quality assurance and quality

control tests
90%
Through Final Bill

B)
(Along with Record Drawings, Quality Assurance reports as per
Para 2.2, Page No. Em-1) 100%
49
2.6 FILTER MATERIALS (ITEM NO. EW 24-EW 25)
2.6.1 SCOPE. - The item shall include furnishing of tools, plant, labour and
materials required for providing and laying approved materials in the specified layers
including screening and washing the materials if necessary, compaction and all
operations necessary and ancillary thereto.
2.6.2 MATERIALS .- (a) The materials for filling the drains or drainage mats or
slant drains, shall consist of sand gravel and crushed metal suitably graded to satisfy the
filter criteria.(IS 383-2016 (for material properties) and IS 9429-1999 (for drainage
system) and amended from time to time.)
(1) the coefficient of permeability of draining material should be more than 6 times that
of base material,
(2) Following criteria should be satisfied by the well graded sand to be
used the filter i)Co-efficient of uniformity
D60/ D10 >4
ii)Co-efficient of
curvature
(D30)2/ D60 x D10 >4
It should also satisfy the following filter criteria with the base material immediately in
contact with.
i) D 15(Sand)/ D 85(Base Material) <5
ii) D15 (filter material) / D15 (base material) > 4 and <20
iii) D 50 (Sand) / D 50 (Base Material) <25
iv) Gradation curve of sand should be roughly parallel to that of base material.
and as decided by the Engineer - in - charge. The sizes of the materials shown on the
drawings are tentative and may require modifications if they are not found to satisfy
filter criteria. The contractor shall be bound to carry out such modifications as directed
by the Engineer - in - charge without any extra cost.
(b) Sand:- The sand shall be natural sand or crushed sand. It shall be from hard, dense
and durable rock formations. The maximum percentage of materials less than 0.074
mm. size shall be 5 per cent by weight and it should not contain organic materials. The
maximum size of particle shall be 10 mm. (3/8 inch.). The specific gravity of particles
shall be not less than 2.60. The sand shall be well graded, and it should satisfy the filter
criteria with the adjoining filter and base materials. If necessary the sand may have to
be washed or screened with any extra cost. The sand is to be supplied by the contractor
from approved quarries and the item includes all charges of supply and rehandling
including collecting, screening, transporting, washing, stacking, etc. with all leads and
lifts involved for supply of sand.
50
(c) Gravel - When gravel is to be used it shall mean natural gravel consisting of clean
hard, durable dense, rock fragments. It shall be well graded subject to clause (a) above.
The percentage of materials below 0.074 mm. size shall be less than 2 per cent. The
gravel should not contain any organic matter. The item includes all charges of supplying
and rehandling, including collecting, screening and washing if necessary, transporting,
stacking etc., with all leads and lifts involved for supply of gravel.
(d) Metal. - If natural gravel deposits satisfying filter criteria are not available the use
of metal shall be permitted as filter material. The maximum size permissible shall be
75 mm. Metal shall consist of broken or crushed rock, having clean, hard, durable,
dense rock pieces. It shall be reasonably well graded with sizes as shown on the drawing
subject to clause (a) above. The percentage of materials below 0.074 mm. size shall be
less than 1 per cent. The item includes all charges of supply and rehandling including
breaking, screening, transporting, stacking, etc. , with all leads and lifts involved for
supply of metal. The sizes of the metal shown on the drawings are tentative and subject
to change as required to satisfy the filter criteria with adjacent materials.
(e) Quarry Spalls- The quarry spauls shall consist of clean, hard, durable, dense rock
supply rehandling, breaking bigger pieces, transporting, stacking etc. with all leads and
all lifts.
2.6.3 PLACING OF MATERIALS
2.6.3.1 Trench Drains and Mound Drains- (a) The excavation for the trench either in
natural ground or made up bank work shall be as per designed cross sections or as
directed in writing by the Engineer in - charge and is recovered under the item of
excavation. The surface of excavation shall be cleaned of all loose material so as to
prevent contamination with the filter materials. Similarly the surface on which the
mound drains are to be laid is to be cleaned of all loose materials.
(c) The filter materials shall then be fully deposited in different layers to the required
thickness and slopes and grades as shown in the drawings or as directed by the Engineer
- in - charge. Thickness of individual layers shown on the drawings are tentative and
may require modifications to satisfy filter requirements and the contractor shall be
bound to carry out such modifications as directed by the Engineer in - charge without
any extra cost. The courser materials shall form the core of the drain with an all-round
cover of progressively finer materials. The laying of individual layers shall proceed in
such a way as to preclude as far as possible the mixing of materials of one size with that
of the other.
2.6.3.2 Filter Mats or Drainage Blankets

(a) Filter Mat on the Black soil Foundation. - After the black soil foundations
stripped or excavated to level designed or as directed, the foundation shall be clean of
all loose materials, watered if necessary and lightly rolled by flat roller by making 4 to 6
passes immediately after stripping. After rolling the foundation surface shall be covered
with sand layers and random embankment of thickness as shown on the drawings. The
stripped foundation surface should be covered by random earth fill and then a sand layer
51
after rolling, within two days after stripping that area, to avoid formation of cracks and
loss of moisture in the foundation soil. The sand layer shall be watered if necessary and
compacted with tampers, rollers or any approved equipment to give a relative density
of 70 per cent. The other layers of gravel, metal or sand shall then be laid on the first
sand layers within a week after the first sand layer is laid. The filter materials shall be
carefully deposited in different layers to the required thickness and slopes and grades as
shown in drawing or as directed
The thickness and grading of individual layers shown on the drawings are tentative and
may require modifications to satisfy filter and drainage requirement and contractor shall
be bound to carry out such modifications as directed by the Engineer in - charge without
any extra cost. The coarser materials shall form the core of the mat with a cover on top
and towards the bottom of progressively finer materials. The laying of the individual
layers shall proceed in such a way as to preclude as far as possible the mixing of
materials of one size with that of the other. After the top layer is laid, it will be watered
if necessary and compacted with tampers, rollers or any approved equipment to give a
relative density of more than 70 per cent.
(b) Filter Mat on non - Black Soil Foundation Mat and on Embankment Already laid
at Intermediate Levels. The foundation surface and the surface of embankment shall be
cleaned of loose material and should be as far as possible plane having no large hollows
or humps, and with slope as shown on the drawings or as directed. The filter materials
shall then be deposited in different layers to the required thickness and slopes and
grades as shown on the drawings or as directed by the Engineer in - charge, The
thickness of individual layers shown on the drawing are tentative and may require
modifications to satisfy filter and drainage requirements and the contractor shall be
bound to carry out such modifications as directed by the Engineer in - charge without
extra cost. The coarser materials shall form the core of the mat with a cover on top and
bottom of progressively finer materials. The laying of the individual layers shall proceed
in such a way as to preclude as far as possible the mixing of materials of one size with
that of the other.
The layers of sand shall be watered if necessary and compacted with tampers, rollers or
any approvedequipment so as to achieve relative density of more than 70 per cent.
2.6.4.1 Trench Drains and Mound Drains .-- The measurements shall be of the
volume of the total quantity of filter material placed. The cross sections of drains as
finally approved and constructed shall be recorded. In case of a trench drain the bottom
width and bottom levels and side slopes shall be as recorded for the item of excavation.
Any material filled in excavation beyond approved section will not be paid for. The rate
includes all leads and liſts.
2.6.4.2 Filter Mat or Drainage Blankets (a) Filter Mat in Black Soil Zone --- The
work shall be measured on the basis of cross sections taken at every 15 meters or at less
distance at directed. The cross section shall be taken before laying the drainage mat and
then after completion. The quantities of sand, gravel or metal will be recorded
separately for different type of materials and paid for accordingly. The rate includes all
leads and lifts
52
(b) Filter Mats on Embankment Already Laid - The work shall be measured on the
basis of cross section taken at every 15 meters or at lss distance as directed. The cross
section shall be taken before and after laying the filter mat. The quantities of sand gravel
or metal will be recorded separately and will be paid for accordingly. The rate includes
all leads and lifts.
2.6.5 PLACEMENT AND COMPACTION :
The sand shall be placed in the filter zone as shown in the drawing and/or as directed by
the Engineer-in-charge. The tolerance in the width of the filter may be 5 cm . The
thickness of layer shall not exceed 23 cm. or as directed by the Engineer-in-charge
depending upon the type of material, moisture content and type of compacting
equipment. The compaction of the sand has to be done, by plate vibrator or rollers till
specified density as below is obtained. Periodical testing of sand will be made in
laboratory and field to find out the maximum density (D-max.), minimum density (D-
min) of the sand and the placement density (D) of the compacted filter. The relative
density of sand (RD) shall be equal to or more than 70% in the test samples taken after
the compaction. No placement of sand is allowed unless the layer is placed and
compacted to desired condition to obtain desired density as above. It is recommended to
place sand density in minimum compactive efforts in dry or in saturated. During
compaction the sand shall not be allowed to flow out of specified width on either side.
The sand shall be confined in between two sheets or plates installed to ensure filter to
have specified width and to avoid contamination of filter due to mixing with adjoining
soil. Atmost care shall be taken to ensure that the material near the junction of filter and
the adjoining placement on both sides is compacted to the stipulated density. During the
construction of sand filter in order to maintain slope or inclination of filter the hearting
must be at higher level and the downstream casing is to be kept a bit below. The process
shall be continued in the same way till end of season. At the end of working season,
the sand filter shall be kept atleast 15 cm. above the adjoining zones to avoid
contamination of soil in the filter sand during rainy season.
The rate quoted by Contractor includes the charges of supply of sand, rehandling it
necessary, collecting, screening (If required), washing (if necessary), transporting
placement in desired shape and laying and compaction to stipulated standard.
2.6.6 MODE OF MEASUREMENT :
The work shall be measured on the basis of cross section. The cross section will be
taken at every 15 m or at closer as decided by Engineer-In-charge. The final width or
thickness of layers at different levels and location from centre line or any reference line
shall be recorded on every 15 m vertical interval and at change of section of filter.
Measurement will be recorded on cross section basis and payment will be made for the
completed item

53
Sr. Percentage of full rate to
Stage
No. be released
1) For Dam
a) Embankment satisfying all quality assurance and

quality control tests
90%
Sr. Percentage of full rate to

Stage
No. be released
Through Final Bill
B)
(Along with Record Drawings, Quality Assurance
reports as per Para 2.2, Page No. Em-1) 100%
2.7 DEWATERING (ITEM NO.EW 26)
2.7.1 GENERAL - The foundation trenches and the building area shall be kept dry
by resort to pumps alone or in combination with manual labour for bailing out water
with buckets, etc. or anyother satisfactory method. The method to be adopted shall
be entirely left to the choice of the contractor provided dewatering is carried out
satisfactorily and the scheduled program is adhered to. The contractor shall plan,
construct, and maintain satisfactorily, safe and Fool - proof arrangement for dewatering
to ensure safe foundation excavation and laying concrete and masonry in the dry.
The contractor shall supply details of his proposals for approval of the Engineer, but
such an approval will in no way release the contractor from his responsibility for the
adequacy of dewatering arrangements and for the quality and safety of the work, for all
of which the contractor shall be solely responsible. Cement grouting or other approved
methods may be used by the contractor at his discretion and cost to prevent or reduce
seepage and to protect the area to be excavated if the soil is porous.
2.7.2 PUMPING - Adequate pumping arrangements shall be made for dewatering

foundation trenches and pools in the building area and keeping the same dry while
excavation, masonry or concreting is in progress and till the mortar has sufficiently set.
Pumps of required capacity and in required number and stages shall be provided to
ensure the above. Pumping from the foundation trenches shall be done directly from
the foundation trenches or from a sump outside the excavation as necessary, in such a
manner as to preclude the possibility of movement of water through any fresh
concrete or masonry and washing away parts of concrete or mortar. No pumping
shall be allowed during laying of concrete or masonry and for a period of at least 24
hours thereafter unless it is done from a suitable sump separated from concrete or
masonry by effective means. Pumping shall be done in such a way as not to cause
damage to the work or adjoining property by blows, subsidence etc. The contractor
shall make his own arrangements for necessary labour, materials, pumps, engines,
54
well-points, and other suitable machinery and devices required for successful execution
of the item ofdewatering.
2.7.3 DE-SILTING - If any foundation pits are filled due to accumulation of surface
flow during theprogress of the work or during rainy season or due to any other cause, all
pumping required for dewatering the pits and removing silt shall be done without extra
cost.
2.7.4 SHORING ETC: - Staging, shoring, strutting, sumps and other protective
works required for facility of dewatering shall be designed and put up by the contractor
to ensure full safety to the work, workmen, machinery and property and shall be
removed after they have served their purpose in a manner and to the extent directed by
the Engineer. The contractor shall be responsible for all damage and injury caused by the
execution of this item.
2.7.5 DISPOSAL OF WATER - The water from the excavated trenches shall be
disposed off in the manner detailed below or in any other manner in conformity with the
rules in force and approved by the Engineer. (a) In case the area is developed, such as
cities which are severed or have open gutters along the roadside, the water may be led to
the nearest such gutters or sewers. (b) In undeveloped areas such as countryside where
severing system has not been introduced, the water may be led to the nearest natural
drain or pond through properly laid and dug channels or through pipes. Disposal of
water shall in no cause inconvenience or nuisance to the inhabitants of the area or cause
damage to the property and structures nearby. Municipal or Government regulations
shall be complied with and rights of private land owners shall be respected regarding
disposal of water. Contractor shall be responsible for the entire incidental formalities
like obtaining permission of local bodies (Municipalities etc.) and persons concerned, to
lead the water to the open or under ground sewers, or digging up channels, making use
of lands and properties owned by private persons or public bodies etc. and for the
damage caused in the operation of this item
2.7.6 ITEM TO INCLUDE
(1) All labour, materials, pumps, plants, equipment, staging shorting, strutting, sumps
another arrangements necessary for dewatering during excavation and construction of
other items requiring dewatering. (2) Dewatering foundation trenches and construction
area and keeping the same dry while excavation, masonry and concrete work is in
progress and till the work comes above the water level and till the Engineer considers
that the mortar or concrete has sufficiently set. (3) Dewatering till all the items
requiring dewatering are fully completed. This shall also include time required for
passing foundation and taking measurements of all the items requiring dewatering. (4)
Removing stuff of any sort which might find access into the trenches by blowing, slip or
due to any other cause whatsoever from the sides or bottom of the foundation or
excavation or from elsewhere during, after or due to dewatering. (5) Leading water, to
the nearest natural or artificial drains, with all the incidental requirements like taking
permission from Municipal and other authorities and private persons concerned pay in
compensations etc. (6) Compensation for the injury to the workman and the public or
damage to the nearby properties during and on account of dewatering and disposal of
water.
55
2.7.7 MODE OF MEASUREMENT AND PAYMENT –
The item shall be measured in BHP-hr.The payment of dewatering shall be lump sum
for the complete job or for each sub item as provided in the tender by any suitable and
acceptable method of dewatering approved by the Engineer and for the depths shown on
the drawings and up to 1.5 meters below such depths. The rate for dewatering shall not
be reduced if the depth of dewatering is less than that shown in the drawings provided
dewatering is actually required and done. Dewatering required for excavation and other
items below this additional depth of 1.5 m. will be paid for as extra work, rate for which
will be fixed according to the general terms of the contract. Full payment for the job of
dewatering shall be made after completing the structural work upto the ground level or
to such level beyond which no dewatering will be required either for construction or for
allowing the mortar or concrete to set.
56
For Office Use Only
SECTION 3
SPECIFICATION FOR
CONCRETE WORK INCLUDING CENTERING, UCR MASONRY.

BRICK MASONRY AND R.C.C. PIPES
2022-23
57
SECTION 3: CONCRETE WORK INCLUDING CENTERING, UCR MASONRY.
BRICK MASONRY AND R.C.C. PIPES
3.1 PLAIN AND REINFORCED CEMENT CONCRETE WORK

(Item No. CC1 - CC7 & CC13 - CC18)
3.1.1 DESCRIPTION OF ITEM:

Providing all materials required for concrete production of all grades and MSAs and laying
the concrete in-situ with all leads and lifts, including compaction, curing, testing and
providing all materials for formwork, centering, shuttering, staging required for the work
etc. all complete.
3.1.2 SCOPE OF WORK

The specifications cover the general requirements for concrete jobs, using on-site
production facilities, including requirements in regard to the quantity, handling, storage of
ingredients, proportioning, batching, mixing and testing of concrete and also requirements
in regard to the quality assurance. This also covers the transportation of concrete from the
mixer to the place of final placement and the placing, compaction, curing, protecting,
repairing and finishing of concrete. The quality of materials, method and control on
production and transportation of concrete for all works, whether reinforced or otherwise,
shall conform to these specifications as applicable. The Engineer-in-charge shall have the
right to inspect the sources of materials, operation of procurement and the layout of storage
of materials, the concrete production facility (including batching and mixing plant) and the
quality assurance/control system. The inspection by Engineer-in-charge or authorized
representative shall be assisted by the contractor, and the Engineer-in-charge's approval
shall be obtained prior to starting the concrete work. IS: 456 and other relevant Indian
Standards (as listed at the end) with their latest revisions and amendments as current on the
date of work shall be applicable, except the deviations laid down in these specifications.
The concreting shall be done with mix proportion after MIX DESIGN prepared and
approved by government authorized laboratory only, except otherwise approved by
competent authority.
All IS referred shall be of latest edition with the latest amendments.
3.1.3 MATERIAL SPECIFICATION

3.1.3.1 Water
1. Water used for mixing and curing shall be, clean and free from injurious materials or any
amount of oils, alkalis, sulphates, chlorides, acids, oils, salts, sugar, organic materials,
vegetable growth or other substances that may be deleterious to concrete or steel. Potable
water is generally considered satisfactory for mixing concrete. The pH value of water
shall be not less than 6.
2. The permissible values of deleterious materials found as per respective parts of IS 3025
shall conform to limits of IS 456 and its revisions.
3. The physical and chemical properties of water from a particular source shall be tested
along with soil investigation and if the water is not found conforming to the requirements
of IS 456, the contractor has to arrange good quality water for construction indicating the
58
source. If water of acceptable quality is not available in required quantity, the water shall
be treated to make it useful for the work. No payment shall be paid to the contractor for
testing and treatment of water.
4. Water found satisfactory for mixing is also suitable for curing. However, water used for
curing shall not produce any objectionable stain or unsightly deposit on the surface.
5. Sea water shall not be used for mixing or curing of concrete because of presence of
harmful salts. However, it can be used with proper treatment and permission from
Engineer-in-charge.
6. Water from each source shall be tested before the commencement of the work from
accredited laboratory (if private) or from any Government Laboratory and thereafter once
in every season till the completion of the work.
3.1.3.2 Cement and Cementations Materials

Unless otherwise specified or called for in the contract specifications, cement used shall
be any of the following and the type selected should be appropriate for the intended use
and as per the contract conditions, specifications and drawings.
a) 33 Grade ordinary Portland cement conforming to IS 269
b) 43 Grade ordinary Portland cement conforming to IS 8112
c) 53 Grade ordinary Portland cement conforming to IS 12269
d) Portland slag cement conforming to IS 455.
e) Portland Pozzolana cement (fly ash based) conforming to IS 1489(Part 1)
f) Portland Pozzolana cement (calcined clay-based conforming to IS 1489 (Part 2)
g) Sulphate resisting Portland cement conforming to IS 12330.
In case the job requires specific use of any other cement the same shall be used with the
prior approval of the Engineer-In-Charge and necessary precautions with regard to their
setting and hardening time, time required for de-shuttering, curing etc., shall be taken
after carefully complying with specific literature with regard to those types.
Combinations of Portland Cement with mineral admixtures of quality conforming to

relevant Indian Standards may also be used in the production of concrete, provided that
there are satisfactory data on their suitability, such as performance test on concrete
containing them, and only in such case where in specifically called for in the contract.
• Contractor shall supply Manufacturer’s certificate conforming the cement to
specifications.
• The Contractor shall make his own arrangements for the storage of adequate quantity of
cement at no extra cost at the site of work as per specifications, instructions and approval
of the Engineer-in-Charge.
• Cement shall be tested by taking samples from the cement stored for the work.
• On the basis of manufacturer’s certificate, the contractor can use the fresh cement at his
own risk before the test results are available. If tests indicate cement to be not conforming
to the requirements, the contractor shall reconstruct the work done, as per guidance of
Engineer-in-Charge.
59
3.1.3.3 Mineral Admixtures
• The mineral admixtures as per IS 456 (Latest version) clause 5.2. can be used in concrete.
• For use of mineral admixtures, highly efficient mixers are necessary. Pan mixers and
double shaft mixers in batch mixing plants are normally efficient mixers.
• For blending of mineral admixtures, tilting drum mixtures are not permitted.
1. Pozzolana:
Pozzolanic materials conforming to relevant Indian Standards may be used with the
permission of Engineer-in-charge, provided uniform blending with cement is ensured.
2. Fly ash (Pulverized Fuel Ash (PFA)):

Fly ash conforming to Grade 1 of IS 3812 may be used as part replacement of ordinary
Portland cement provided uniform blending with cement is ensured.
3. Ground Granulated Blast Furnace Slag:

Ground granulated blast furnace slag obtained by grinding granulated blast furnace slag
conforming to IS 12089 may be used as part replacement of ordinary Portland cement
provided uniform blending with cement assured.
4. Silica fume (micro-silica):

Silica fume conforming to IS 15388 or approved by the Engineer-in-Charge can be used
as part replacement of cement provided uniform blending with the cement ensured.
Note: The silica fume (very fine non–crystalline silicon dioxide) a by-product of the
manufacture of silicon, ferro-silicon or the like, from quartz and carbon in electric arc
furnace. The particle size much below 1 micron.
5. Rice husk ash:

Rice husk ash giving required performance and uniformity characteristics may be used
with the approval of the Engineer in Charge.
Note: Rice husk ash produced by burning rice husk and contains large proportion of silica.
To achieve amorphous state, rice husk may be burnt at controlled temperature. It is
necessary to evaluate the product from a particular source for performance and uniformity
since it can range from being as deleterious as silt when incorporated in concrete. Water
demand and drying shrinkage should be studied before using rice husk.
6. Metakaolin:
Metakaoline having fineness between 700 to 900 m²/kg may be used as Pozzolanic
material in concrete.
Note: Metakaolin obtained by calcination of pure or refined kaolinitic clay at a

temperature between 6500C and 8500C, followed by grinding to achieve a fineness of 700
to 900 m²/kg. The resulting material has high pozzolonicity.
A certified Test report attesting to the conformity of the mineral admixtures

specifications shall be furnished to the Engineer-in-Charge.
60
3.1.3.4 Supply of Cement and Cementations Materials:
Cement:
a) Bags: The cement shall be packed in jute sacking bags conforming to IS 2580, double
hessian bituminized (CRI type) or woven HDPE conforming to IS 11652. Woven
polypropylene conforming to IS 11653, jute synthetic union conforming to IS 12174, or
any other approved composite bags,
b) bearing the manufacturer’s name or his registered trade mark if any, with grade batch no.
and type of cement, year and week of manufacturing of batch of cement.
Each bag shall weigh 50 Kg or more. Tolerance requirements for the mass of cement
packed in bags shall be as per the relevant Indian Standards.
Bulk Supply: Alternatively, cement can be procured in bulk by transporting in cement
bulkers and stored in cement silos at mixing plant. Transport and storage of cement in
bulk is preferable.
c) Test: i) Every delivery of cement shall be accompanied by a Manufacturer’s certificate
conforming that the supplied cement conforms to relevant specifications. These
certificates shall be endorsed to the Engineer-in-Charge for his record.
ii) Every consignment of cement must have identification marks on packages indicating
W-M-Y of manufacturing grade and type of cement batch no. etc.
iii) As far as possible fresh cement shall be procured.
iv) Cement brought to works shall not be more than 6 weeks old from the week of
manufacture.
v) If stocks are more than 6 weeks old, the cement shall be retested and report submitted
to the Engineer-in-Charge.
vi) Supplies of cement in bulk may be made by arrangement between the purchaser and
the supplier (manufacturer).
NOTE- a single bag or container containing 1000 kg and more, net quantity of cement
shall be considered as the bulk supply of cement.
Storage of Cement and Cementations Materials

The Contractor will have to make his own arrangement for the storage of adequate
quantity of Cement. The Storage of the Cement shall be made as per the provisions of IS
4082.
Cement in bags shall be stacked and stored in a shed, which is dry, leak-proof and
moisture proof as far as possible. Storage under tarpaulins will not be permitted. Flooring
of the shed shall consist of the two layers of dry bricks laid on well consolidated earth.
To avoid contact of cement bags with the floor, stacking shall be done about 150 to 200
mm clear above the floor using wooden planks. Cement bags shall be stacked at least 450
mm clear off the walls and in rows of two bags leaving in a space of at least 600 mm
between two consecutive rows. In each row the cement bags shall be kept close together
so as to reduce air circulation. Stacking shall not be more than ten bags high to avoid
lumping under pressure. In stacks more than eight bags high, the cement bags shall be
arranged in header and stretcher fashion i.e., alternately lengthwise and crosswise so as
to tie the stacks together and minimize the danger of toppling over.
Damaged or reclaimed or partly set cement will not be permitted to be used and shall be
removed from the site. The storage arrangements shall be such that there is no dead
61
storage consignments in cement shall be stored as received and shall be consumed in the
order of its receipt i.e. ‘first in- first out’.
Cement held in store for a period of ninety (90) days from date of manufacturing or longer
shall be retested before use in work. Should at any time the Engineer-in-Charge have
reasons to consider that any cement is defective, then irrespective of its origin and/or
manufacturers test certificate, such cement shall be tested immediately at a Quality
Control/Quality Assurance Laboratory or such approved laboratory, and until the results
of such tests are found satisfactory, it shall not be used in any work.
In case cement is received in silos, the silos shall be placed near the concrete batching
plant. Proper access shall be provided for the refilling of silos.
3.1.3.5Fine Aggregates
General:
Fine aggregate shall consist of (1) Uncrushed (Natural) Sand, (2) crushed sand, or (3)
Manufactured Sand, all conforming to IS: 383. The fine aggregates shall be clean, sharp,
hard, strong and durable and shall be free from dust, vegetable substances, adherent
coating, clay, shale, loam, alkali, organic matter, mica, salt, soft particles, or other
deleterious substances which can be injurious to the setting qualities/strength/durability
of concrete. For limits of presence of mica, refer IS 383.
Foreign Material Limitations:

The percentages of deleterious substances in fine aggregates, delivered to the mixer shall
not exceed the following:
Table 1
Sr. Percentage by Weight
Substances
No. Uncrushed Crushed/Manufactured
1 Material finer than 75-micron I.S. Sieve 3 15
2 Shale 1 -
3 Coal and lignite 1 1
4 Clay lumps 1 1
5 Total of all above substances 5 2
Gradation:
Unless otherwise directed or approved, the grading of fine aggregates shall be done into one of
the zones indicated below by proper test.
Table 2
I.S. Sieve Designation Percentage Passing for
Zone I Zone II Zone III Zone IV
10 mm 100 100 100 100
4.75 mm 90-100 90-100 90-100 95-100
2.36 mm 60-95 75-100 85-100 95-100
1.18 mm 30-70 55-90 75-100 90-100
600 microns 15-34 35-59 60-79 80-100
300 microns 5-20 8-30 12-40 15-50
62
I.S. Sieve Designation Percentage Passing for
Zone I Zone II Zone III Zone IV
150 microns 0-10 0-10 0-10 0-15
Where the grading falls outside the limits of any particular grading zone of sieves, other
than 600-micron (I.S.) sieve by not more than 5%, it shall be regarded as falling within
that grading zone. This tolerance shall not be applied to percentage passing the 600-
micron (I.S.) sieve or to percentage passing any other sieve size on the coarser limit of
grading zone I or the finer limit of grading zone IV. Fine aggregates conforming to
Grading Zone IV shall not be used unless mix designs and preliminary tests have shown
its suitability for producing concrete of specified strength and workability.
Fineness Modulus (FM):

The fine aggregates shall normally have a fineness modulus of not less than 2.6 or more
than 3.2. Fine aggregates with fineness modulus very high or very low can be used after
many trials after specific Mix Proportioning.
Moisture Content:
Quantity of fine aggregates shall be suitably adjusted to account for Moisture Content in
sand by weight.
Storage of aggregates:
All coarse and fine aggregates shall be stacked separately in stock piles in the material
yard near the mixer in bins properly constructed to avoid inter mixing of different
aggregates. Contamination with foreign materials and earth during storage and while
heaping the materials shall be avoided. Storage area should have a flooring to avoid
contamination with soil and dust from below, alternatively if stored on ground; the bottom
200 mm of aggregate shall not be used. The aggregate must be of specified quality not
only at the time of receiving at site but also at the time of loading into mixer. Rakers shall
be used for lifting the aggregate from bins or stock piles. The Aggregates shall be stacked
in a manner so as to prevent conning and segregation. Each layer shall cover the entire
area of the stock pile before succeeding layers are started. Aggregate shall be stored in
different size fractions separately. Aggregates that have become segregated or can
segregate shall be rejected. Rejected material after sieving and separating may be
accepted, if subsequent tests demonstrate conformity with required gradation. The
Contractor shall at all times maintain a minimum storage of all grades of the aggregate
for the days' requirements, at work site failing which the work may not be commenced.
The Contractor shall furnish representative samples of aggregate proposed for use in the
work at least two months before aggregates are required for use.
3.1.3.6 Coarse Aggregates:

General:
Aggregate most of which is retained on 4.75 mm IS Sieve and contains only as much fine
material as is permitted in IS 383 for various sizes and grading is known as coarse
aggregate. Coarse aggregate shall be specified as stone aggregate, gravel and it shall be
obtained from approved / authorized sources.
63
(a) Stone Aggregate: It shall consist of naturally occurring (uncrushed, crushed or broken)
stones. It shall be hard, strong, dense, non-porous, durable and clean. It shall be free from
veins, adherent coating, deleterious substances, disintegrated pieces, alkali, vegetable
matter and other deleterious substances. It shall be roughly cubical or angular in shape.
Flaky and elongated pieces shall be limited. It shall conform to IS 383 unless otherwise
specified.
(b) Gravel: It shall consist of naturally occurring (crushed, broken, or uncrushed) river bed
shingle or pit gravel. It shall be sound, hard and clean. It shall be free from flat particles
of shale or similar laminated material, powdered clay, silt, loam, adherent coating, alkali,
vegetable matter and other deleterious substances. Pit gravel shall be washed if it contains
soil or softer materials adhering to it. These shall conform to IS 383 unless otherwise
specified.
(c) Light weight aggregate such as sintered fly ash aggregate may also be used provided the
Engineer-in-Charge is satisfied with the data on the proportion of concrete made with
them.
(d) Recycled Aggregates – The Recycled Aggregates shall conform to specifications of IS
383.
Quality of Coarse Aggregates

a) Deleterious Material: Coarse aggregate to be used for reinforced cement concrete shall
not contain any material (e.g., excess salts) liable to attack the steel reinforcement.
Aggregates which are chemically reactive with alkalis of cement shall not be used. The
maximum quantity of deleterious material shall not be more than five percent of the
weight of coarse aggregate when determined in accordance with IS 2386.
The percentages of deleterious substances in the coarse aggregate delivered to the mixer
shall not exceed the following:
Table 3
Percentage by weight of Aggregates

Sr. No. Substances
Uncrushed Crushed
1 Material finer than 75-micron I.S. Sieve 3 3
2 Coal and lignite 1 1
3 Clay lumps 1 1
4 Soft fragments 3 -
5 Total of all the above substances 5 5
b) The Aggregate Crushing value, Impact value, Abrasion value and Soundness shall be as
per provisions of IS 383 and its revisions
c) Combined Flakiness and Elongation Index: Flakiness and Elongation Index shall be
determined in accordance with IS 2386 (Part-1) on the same sample.
64
After carrying out flakiness index the flaky materials shall be removed from sample and
the remaining portion shall be used for determining Elongation Index. The indices so
found shall be added numerically to give Combined Flakiness and Elongation Index. The
Combined Flakiness and Elongation Index shall not exceed 40 percent for uncrushed and
crushed aggregates.
d) Alkali Aggregates Reaction: Some aggregates containing particular varieties of silica

which may be susceptible to attack by alkalis originating from cement and other sources,
producing and expansive reaction which can cause cracking and disruption of concrete.
Damage to concrete from this reaction will normally occur when all of the following are
present together:
• High moisture level within the concrete
• A cement with high alkali content or another source of alkali
• Aggregate containing an alkali reactive constituent
The aggregate shall comply with the requirements when tested in accordance with IS
2386 (Part 7), Additional guidance is available in IS 383.
Size and Grading

(a) Nominal maximum sizes of graded stone aggregate or gravel shall be 40, 20, 16, or 12.5
mm as specified. For any one of the nominal sizes, the proportion of other sizes as
determined by the method prescribed shall be in accordance with table 4
Table 4
IS Sieve Percentage passing (by weight) for nominal size of
Designation
40 mm 20 mm 16 mm 12.5 mm
1 2 3 4 5
80 mm 100 - - -
63 mm - - - -
40 mm 95 to 100 100 - -
20 mm 30 to 70 95 to 100 100 100
16 mm - - 90 to 100 -
12.5 mm - - - 90 to 100
10 mm 10 to 35 25 to 55 30 to 70 40 to 85
4.75 mm 0 to 5 0 to 10 0 to 10 0 to 10
This grading shall be used, where grading is not specified by mix proportioning, say for
nominal mixes
(b) Nominal sizes of single sized stone aggregate or gravel shall be 63, 40, 20, 16, 12.5 or 10
mm as specified. For any one of the nominal size, the proportion of other sizes as
determined by the method prescribed shall be in accordance with Table 5
65
Table 5
Single Sized (Ungraded) Stone Aggregate or Gravel
IS Sieve Percentage passing (by weight) for nominal size of

Designation
63 mm 40 mm 20 mm 16 mm 12.5 mm 10 mm
80 mm 100 - - - -
63 mm 85 – 100 100 - - -
40 mm 0 – 30 85 - 100 100 - -
20 mm 0–5 0 - 20 85 – 100 100 -
16 mm - - - 85 - 100 100
12.5 mm - - – - 85 - 100 100
10 mm 0–5 0-5 0 – 20 0 - 30 0 - 45 85 - 100
4.75 mm - - 0–5 0-5 0 - 10 0 - 20
2.36 mm - - - 0-5
(c) Coarse Aggregates for Mass Concrete works shall be in the size specified as in table
6.
Table 6
Sr. No. Class and Size IS Sieve Designation Percentage Passing
1 2 3 4
160 mm 90 to 100
I Very Large, 150 to 80 mm
80 mm 0 to 10
80 mm 90 to 100
ii Large, 80 to 40 mm
40 mm 0 to 10
66
Sr. No. Class and Size IS Sieve Designation Percentage Passing
1 2 3 4
40 mm 90 to 100
iii Medium, 40 to 20 mm
20 mm 0 to 10
20 mm 90 to 100
iv Small, 20 to 4.75 mm 4.75 mm 0 to 10
2.36 mm 0 to 20
This grading shall be used, where grading is not specified by mix proportioning, say for
nominal mixes
(c) Stone aggregate or gravel should be brought to site as single sized (ungraded) separately,
it shall be mixed with single sized aggregate of different sizes in the proportion to be
determined by field tests to obtain graded aggregate of specified nominal maximum size.
For the required nominal maximum size, the proportion of other sizes in mixed aggregate
as determined by method prescribed shall be in accordance with Table 7. Recommended
proportions by volume for mixing of different sizes of single size (ungraded) aggregate
to obtain the required nominal size of graded aggregate are given in Table 7. This is
applicable to nominal mixes only.
Table 7
Single Sized (Ungraded) Stone Aggregate or Gravel
Nominal Size of graded Parts of Single size aggregate of size

Cement concrete aggregate required
50 40 20 10
12.5 mm
mm mm mm mm
(1) (2) (3) (4) (5) (6) (7)
1:6:12 63 9 - 3 - -
1:6:12 40 - 9 3 - -
1:5:10 63 7.5 - 2.5 - -
1:5:10 40 - 7.5 2.5 - -
1:4:8 63 6 – 2 - -
1:4:8 40 - 6 2 - -
1:3:6 63 4.5 - 1.5 - -
1:3:6 40 - 4.5 1.5 - -
67
Nominal Size of graded Parts of Single size aggregate of size
Cement concrete aggregate required
50 40 20 10
12.5 mm
mm mm mm mm
1:3:6 20 - - 4.5 - 1.5
1:2:4 40 - 2.5 1 - 1.5
1:2:4 20 - - 3 - 1
1:2:4 12.5 - - - 3 1
1:11/2:3 20 0 0 2 - 1
Note: The proportions indicated in Table 7 above are by volume when considered
necessary, these proportions may be varied marginally by Engineer-in-Charge after
making sieve analysis of aggregate brought to site for obtaining required graded
aggregate. No adjustments in rate shall be made for any variation in the proportions so
ordered by the Engineer-in-Charge. If single size coarse aggregate is not premixed at site
to obtain the graded coarse aggregate required for the mix, the volume of single size
aggregates required for the mix shall be suitably increased to account for reduction in
total volume at the site of mixing.
3.1.3.7 Chemical Admixtures

General: Chemical admixtures of approved quality shall be mixed with concrete, as
specified. The admixtures shall conform to IS 9103 and its subsequent revisions.
Admixtures should not impair durability of the concrete, not combined with the
constituents to form harmful compounds, nor increase the risk of corrosion of
reinforcement. The workability, compressive strength and the slump loss of concrete with
& without the use of admixtures shall be established during the trial mixes before use of
admixtures. Most of commercially available admixtures are formulations i.e., mixture of
different liquids and compounds. During storage matter settles, and density across the
depth varies. The relative density of liquid admixtures shall be checked from drum
containing admixtures after proper agitating or mixing, and compared with the specified
value before acceptance. The chloride content of the admixtures shall be independently
tested for each batch before acceptance. Admixtures should be compatible with particular
cement (from a specific plant) and this should be ascertained and certified by the
admixture manufacturer. The combination should give consistent results which are not
erratic. If source of either cement or admixture is changed, the compatibility trials and
mix design (proportioning) shall be freshly done.
a) Admixtures introduced into the concrete as liquids (solutions or suspensions) shall fall
into the following categories.
• Accelerating admixtures,
• Retarding admixtures,
• Water-reducing admixtures,
• Air-entraining admixtures, and
68
• Super plasticizing admixtures.
b) Dosage of these admixtures may vary according to manufacturer’s specification and the
requirements of properties in concrete. The supplier or Manufacturer should specify the
maximum limit of dose usable.
c) Two or more admixtures may not be compatible in the same solution. It is therefore
mandatory that when two admixtures manufactured by the same manufacturers are being
used simultaneously, the manufacturer shall certify their compatibility. In case the two or
more admixtures are produced by different manufacturers, then, before their use in
concrete, test shall be performed by a laboratory to establish their compatibility and
consistency of results, all such test reports shall be furnished to the Engineer-in-Charge
for his approval before their use in concrete.
d) Some admixture may be in the form of powder, particle or high concentration liquids
which may require mixing with water prior to dosing. For all admixtures being added in
liquid or solution form, volume liquid / solution shall be considered as part of total water
content in the batch of concrete in order to maintain the water-cement ratio.
e) Admixture manufacturer’s recommendation shall be carefully followed so as to ensure
complete solution of the product or to prepare a standard solution of uniform strength for
easier use. Most admixtures being formulations, on storage may have different density in
the portions of drum or tank. Hence the admixtures shall be well stirred or agitated to
make it uniform as per the manufacturer’s instruction, just before use.
f) Certain admixtures may contain significant amounts of finely divided insoluble materials
or active ingredients which may or may not be readily soluble. It is essential for such
admixtures that precautions be taken to ensure that these constituents be kept in a state of
uniform suspension before actual batching. When relatively small amounts of powered
admixtures are to be used directly, these shall be pre-blended with cement.
g) Admixtures are sold under various trade names and may be in the form of liquids or
powders. The proprietary name and the net quantity of content shall be clearly indicated
in each package or container of admixtures and along with necessary test certificates. The
admixtures shall be uniform within each batch and uniform between all batches.
h) The compatibility of admixtures with cement shall be got tested before use at the
contractor’s expense and such Certificate shall be submitted to Engineer in Charge.
i) No admixtures shall be accepted for use in concrete unless these are tested in accordance
with IS 9103.
j) Chloride content in admixture shall be declared, and admixtures containing chlorides
shall not be used, unless specific permission is taken from Engineer-in-Charge.
Storing and Dispensing Chemical Admixtures

• Liquid admixtures can be stored in barrels or bulk tankers. Powdered admixtures can be
placed in special storage bins and some are available in premeasured plastic bags.
Admixtures added to a truck mixer at the jobsite are often in plastic jugs or bags.
Powdered admixtures, such as certain plasticizers, or a barrel of admixture may be stored
at the project site.
• Dispenser tanks at concrete plants should be properly labeled for specific admixtures to
avoid contamination and avoid dosing the wrong admixture. Most liquid chemical
admixtures should not be allowed to freeze; therefore, they should be stored in heated
environments. The Manufacturer shall provide information for proper storage
69
temperatures. Powdered admixtures are usually less sensitive to temperature restrictions,
but may be sensitive to moisture.
• Liquid chemical admixtures are usually dispensed individually by volumetric
measurement, in the water batched to be added to mixer. Liquid and powdered admixtures
can be measured by mass, but powdered admixtures should not be measured by volume.
Admixture in powder form cannot be directly added to mixer. It should either be pre-
blended with cementations content, or added as solution or suspended already prepared.
Care should be taken not to combine certain admixtures prior to their dispensing into the
batch as some combinations may neutralize the desired effect of the admixtures. The
Manufacturer shall provide certificate regarding compatibility of the admixture with the
particular Cement (from a specific plant) proposed to be used.
3.1.3.8 Concrete Mix Proportioning

General
This is to investigate the grading of aggregates, water cement ratio, workability and the
quantity of cement required to give the concrete the desired characteristic strength. The
proportions of the mix shall be determined by weight. Adjustment of aggregate
proportions due to moisture present in the aggregate shall be made. Mix proportioning
shall be carried out according to the IS: 10262 or any other well-established method. If
the mix proportioning arrived at gives satisfactory properties in the concrete as required,
the mix proportioning (/mix design) is acceptable irrespective of the method of design.
Based on the previous experience mix can be adjusted to give the required performance.
In some cases, reference can be made to IRC 44.
After award of the work, if so desired by the contractor, he / they may be allowed by the
Engineer-in-Charge, till the designed mix is obtained, to carry out the reinforced concrete
work in foundation and plinth as per equivalent nominal mix against the specified design
mix concrete as per IS Codes. However, all other specification for design mix shall govern
for nominal mix also and nothing extra shall be paid for use of extra cement or else on
this account whether the cement is supplied by the Department or procured by the
contractor. Prior permission from competent authority shall be obtained in such case
before start of work. In such a case specified mix can also be used, which is based on past
experience.
No concrete work shall be carried out without concrete mix design.
Grades of Concrete
All concrete in the works shall be "Design Mix Concrete" as defined in IS 456. All
"Design Mix Concrete" work to be carried out under these specifications shall be in grades
designated as per table 8 below:
70
Table 8
Specified Characteristic Compressive Strength

Group Grade Designation
of 150 mm Cube at 28 Days in N/mm2
1 2 3
M10 10
Ordinary Concrete M15 15
M20 20
M25 25
M30 30
M35 35
M40 40
M45 45
M50 50
Standard Concrete M55 55
M60 60
M65 65
M70 70
M75 75
High Strength M80 80

Concrete M85 85
M90 90
M95 95
M100 100
NOTE:
1. In the designation of a concrete mix, letter "M" refers to the mix and the number to the
specified characteristic compressive strength of 150 mm. size cubes at 28 days expressed
in N/mm2.
2. Mixes leaner than M10 shall be nominal or specified mixes, unless specified otherwise.
3. Where leaner mixes are required in large quantities, it is preferable to arrive at a proper
grading of aggregates and mix proportioning.
71
3.1.3.9 Water Cement Ratio
For durability of the concrete, the permeability of concrete should be limited to the exposure
condition constituting the mechanisms of loss of durability. For each mechanism of
deterioration there will a safe combination of permeability and clear cover giving a desired life
of structure. In absence of testing and specifying permeability, for control maximum water-
cement ratio is being specified.
For different class of exposures, maximum water-cement ratio, minimum cement content, and
minimum grade of concrete shall be as in table 9.
Table 9
Plain Concrete Reinforced Concrete
Sr. Minimum Maximum Minimum Maximum

Exposure Minimum Minimum
No. Cement Free Water Cement Free Water
Grade of Grade of
Content Cement Content Cement
3 Concrete Concrete
Kg/m Ratio Kg/m3 Ratio
(1) (2) (3) (4) (5) (6) (7) (8)
(¡) Mild 220 0.60 - 300 0.55 M20
(¡¡) Moderate 240 0.60 M15 300 0.50 M25
(¡¡¡) Severe 250 0.50 M20 320 0.45 M30
Very
(¡V) 260 0.45 M20 340 0.45 M35
Severe
(V) Extreme 280 0.40 M25 360 0.40 M40
Notes:
1. Cement content prescribed in this Table 9 is irrespective of the grades of cement. The
additions such as fly ash or ground granulated blast furnace slag may be taken into account
in the concrete composition with respect to the cement content and water-cement ratio, if
the suitability is established and as long as the maximum amounts taken into account do
not exceed the limit of pozzolana and slag specified in IS 1489 (Part 1) and IS 455
respectively.
2. Minimum grade for plain concrete under mild exposure condition is not specified.
3. Concrete grade specified in drawing or contract may be higher than that given in table above.
4. The above minimum cement content and maximum water cement ratio apply only to 20 mm
nominal maximum size. Adjustments to Minimum Cement Contents for Aggregates Other
Than 20 mm Nominal Maximum Size shall be as per Table 10 below.
5. Overall cement consumption for individual items during working season
shall be within (+) or (-) 2%. In case the cement consumption is less than
72
2% than that specified, the work shall be paid at reduced rates.
Table 10
Nominal Maximum Aggregate Adjustment to minimum cement contents in

Sl. No.
Size, mm table 9
1 2 3
1 10 + 40
2 20 0
3 40 - 30
This table is for adjusting paste quantity to get a standard workability
3.1.3.10 Standard Deviation

The standard deviation for each type and grade of concrete shall be calculated, separately
from its past test record.
Standard deviation based on test strength of sample

a) Number of test results of samples: The total number of test strength of samples required
to constitute an acceptable record for calculation of standard deviation shall be not less
than 30. Attempts should be made to obtain the 30 samples, as early as possible, when a
mix is used for the first time.
b) In case of significant changes in concrete: When significant changes are made in the
production of concrete batches (for example changes in the materials used, mix design.
equipment or technical control), the standard deviation value shall be separately
calculated for such batches of concrete.
c) Standard deviation to be brought up to date: The calculation of the standard deviation
shall be brought up to date after every test.
Standard Deviation for assumption in initial Stage

Where sufficient test results for a particular grade of concrete are not available, or at the
beginning of a project, the value of standard deviation given in table below may be
assumed for design of mix in the first instance. As soon as the results of samples are
available, actual calculated standard deviation shall be used and the mix proportioned
properly. However, when adequate past records for a similar grade exist and justify to the
designer of mix a value of standard deviation different from that shown in table below, it
shall be permissible to use that value. However, the minimum standard deviation used for
the mix design shall not be less than that given in column 3 of table 11.
73
Table 11
Grade of Assumed Standard Standard Deviation for mix proportioning not

Concrete Deviation less than
1 2 3
M10
3.5 MPa 2.0 MPa
M15
M20
4.0 MPa 2.5 MPa
M25
M30
M35
M40
M45 5.0 MPa 3.0 MPa
M50
M55
M60
Note: 1) The above values correspond to the site control having proper storage of cement:
weigh batching of all materials, controlled addition of water: regular checking of all
materials, aggregate grading and moisture contents, and periodical checking of
workability, and strength. Where there is deviation from the above the values given in the
above table shall be increased by 1 N/mm2.
2) Standard deviation for mix design shall not be less than value given in 3rd column above,
when it is based on past record.
3.1.4 SEQUENCE OF EXECUTION

3.1.5 FORMWORK (SHUTTERING & SUPPORT) and FALSEWORK
1 General
Formwork shall comply with all provisions of IS 14687 and also the requirements given
herewith. Formwork shall include all temporary or permanent forms or moulds required
for forming the concrete which is cast-in-situ, together with all temporary construction
required for their support.
Except or ordinary and routine jobs, for all large and important jobs, the formwork and
its support or staging shall be designed. Deflection and movement of the formed surface,
is the important consideration of the formwork, whether designed or not.
74
For erecting of formwork, a ‘method statement’ shall be made and got approved from
Engineer-in-charge.
2 General Requirement
It shall be designed and approved by Engineer-in-Charge so as to be strong and stiff
enough to withstand the dead and live loads, all forces and impacts caused by placing,
ramming, vibration and finishing of concrete and other incidental loads, imposed upon it
during and after casting of concrete. It shall be made sufficiently rigid by using adequate
number of ties and braces, screw jacks or hard board wedges where required shall be
provided to make up any settlement in the Formwork either before or during the placing
of concrete. Formwork should be rigid enough such that due to incremental load / pressure
of concrete, variations in live load and equipment actions (loads) do not allow movements
in the plastic concrete which is setting and hardening. If relative movements (deflections)
occur during setting of concrete, there is high possibility of formation of cracks in the
concrete and reducing its inherent tensile strength.
The formwork and all supports should be such that due to vibrations during the
construction operation and equipment use, the connections should not get loosened or
cause displacements.
Form shall be so constructed as to be systematically removable in sections in the desired

sequence, without damaging the surface of concrete or disturbing other sections, care
shall be taken to see that no piece (other than embedment specified) remains in concrete.
RE-USE OF FORMS: Forms required to be used more than once shall be maintained in
serviceable conditions and shall be thoroughly cleaned and smoothened before reuse.
Where metal sheets are used for lining forms, the sheets shall be placed and maintained
on the forms with minimum amount of wrinkles, humps or other imperfections. All forms
shall be checked for shape and strength before-reuse.
3 Material for Formwork

(a) Propping: All propping should be either of steel tubes (readymade props) with extension
pieces or built-up sections of rolled steel. It can also be of any engineered material as per
permission of Engineer-in-charge. Earth centering will not be permissible unless
otherwise Engineer-in-charge is convinced about the site condition.
4 Staging:
(a) Staging should be as designed with required extension pieces as approved by Engineer-
in-Charge to ensure proper slopes, as per design for slabs/ beams etc. and as per levels as
shown in drawing. All the staging to be either of Tubular or hollow sections in steel
structure with adequate bracings as approved or made of built-up structural sections made
from rolled structural steel sections. Staging may consist of proprietary material specially
designed and manufactured for the purpose.
(b) In case of structures with two or more floors, the weight of concrete, and formwork of
any upper floor being cast shall be suitably supported on floor below the floor already
cast. And such supporting floor shall be propped from below as per the approved scheme
of props left over re-propping.
75
(c) Formwork and concreting of upper floor shall not be done until concrete of lower floor
has set at least for 21 days, and lower floor has ‘props left over’, or re-propped where
permissible. For smaller time cycle propping has to be done for several floors as per the
scheme of formwork designed.
5 Shuttering:
Shuttering used shall be of sufficient stiffness to avoid excessive deflection and joints
shall be tightly butted to avoid leakage of slurry. If required, rubberized material as
approved by the Engineer-in-Charge shall be provided in the joints. Steel or plywood
(water-proof) shuttering used or concreting should be sufficiently stiffened. The steel
shuttering should also be properly repaired before use and properly cleaned to avoid
stains, honey combing, seepage of slurry through joints etc. Steel plates used as shuttering
should have surface in one plane with minimum roughness. Shuttering can be provided
with sealing tapes or appropriate lining to make it leak-proof.
The type of shuttering, its smoothness and plainness shall be compatible with the
requirement of the form finished concrete surface or as may be specified.
(a) Runner Joists: RSJ, MS Channel, aluminium sections, manufactured wooden “I” beams
or any other suitable section of the required size shall be used as runners.
(b) Assembly of beam head over props. Beam head is an adopter that fits snugly on the head
plates of props to provide wider support under beam bottoms.
(c) Only plywood or steel shuttering shall be used, except for unavoidable portions and very
small works for which 12 mm thick water-proof ply of approved quality may be used.
Aluminium form with appropriate surface treatment can also be used.
(d) Lost form can be used wherein the elements supporting the new plastic concrete can be
left over as part of permanent structure. These shall be properly designed and are usually
of cementitious product using ferrocement or fibre concrete.
6 Formwork:
It shall be properly designed for self-weight, weight of reinforcement, weight and
pressure of fresh concrete, and in addition, the various live loads likely to be imposed
during the construction process (such as workmen, materials and equipment).
In case the height of props exceeds 3.50 meter, the prop shall be provided in multi-stages.
7 Removal of Formwork (Stripping Time):

Formwork shall not be released or removed unless concrete member is able to support
itself, which cannot be earlier until concrete has achieved strength of at least twice the
stress to which concrete can be subjected at the time of release.
In absence of detailed calculation and strength test of concrete at the age of de-shuttering,
the following guide can be used as applicable. In normal circumstance, as per IS 14687,
forms may generally be removed after the expiry of the following periods for OPC use:
a) Beam sides, wall columns (unloaded) - 16 to 24 hours
b) Slabs and Arches (Props left under) - 4 Days
76
c) Props to slabs:
i) Spanning up to 4.5 m - 7 days
ii) Spanning over 4.5 m - 14 days
Props to beams and archer
i) Sampling up to 6 m - 14 days
ii) Spanning over 6 m - 21 days
d) Lean Concrete - 2 Days
e) Tunnelling and Lining - 24 Days
For use of PPC or fly ash, the above period shall be increased by 25%.
8 Surface Treatment
1. Form coating or release agent:
Shuttering should have a coating or lining which allows easy de-shuttering by reducing
the bond between the shuttering and the concrete. For this purpose, shuttering may have
a permanent coat of epoxy or polymer. Coated plywood for concrete shuttering is
commercially available. Shuttering without suitable coatings, should be applied with
form-releasing agent.
Mould oil shall not be used unless specifically permitted by Engineer-in-Charge. Use of
oil stains the concrete surface. Oil if used shall be washed out before finishing the
concrete surface.
The second categories of de-shuttering agents are Polymer based water soluble
Compounds. There are different types of compounds available in market as de-shuttering
agents. These are available as concentrates and when used diluted with water in the ratio
of 1:20 or as per manufacturer's specifications. The diluted solution is applied by brush
applications on the shuttering both of steel as well as plywood. The solution is applied
after every use.
2. The design of formwork shall conform to latest Engineering practices and relevant IS
codes. For works similar to bridges, IRC documents shall be referred.
9 Inspection of Formwork
The completed formwork shall be inspected and approved by the Engineer-in-Charge
before the reinforcement bars are placed in position. Proper formwork should be adopted
for concreting so as to avoid honey combing, blow holes, grout loss, stains or
discoloration of concrete etc. Proper and accurate alignment and profile of finished
concrete surface will be ensured by proper designing and erection of formwork which
will be approved by Engineer-in-Charge.
Shuttering surface before concreting should be free from debris, any defect/ deposits and
fully cleaned so as to give perfectly straight smooth concrete surface. Shuttering surface
77
should be therefore checked for any damage to its surface and excessive roughness before
use. Its joints should be sealed properly.
10 Erection of Form-work (Props and Shuttering):

Following points shall be borne in mind while checking during erection.
(a) Any member which is to remain in position after the general dismantling is done should
be clearly marked.
(b) Material used should be checked to ensure that, improper items / rejects are not used.
(c) If there are any excavations nearby which may influence the safety of formworks,
corrective and strengthening action must be taken.
(d) (i) The bearing soil must be sound and well compacted and prepared; the sole plates shall
bear well on the ground with enough contact area and avoiding only few contact points.
(ii) Sole plates shall be properly seated on their bearing pads or sleepers.
(iii) The bearing plates of steel props shall not be distorted.
(iv) The steel parts on the bearing members shall have adequate bearing areas.
(v) The bearing arrangement on soil should be such that, due to unexpected rains or small
watering for cleaning and curing shall not cause settlement of props.
(e) Safety measures to prevent impact of traffic; scour due to water etc. should be taken.
Adequate precautionary measures shall be taken to prevent accidental impacts etc.
(f) Bracing, struts and ties shall be installed along with the progress of formwork to ensure
strength and stability of formwork at intermediate stage. Steel sections (especially deep
sections) shall be adequately restrained against tilting; overturning and formwork should
be restrained against horizontal loads. All the securing devices and bracing shall be
tightened.
(g) The stacked materials shall be placed as catered for, in the design of formwork.
(h) When adjustable steel props are used. These should -
1. be undamaged and not visibly bent,
2. have the steel pins provided by the manufacturers for use,
3. be restrained laterally near each end,
4. have means for centralizing beams placed in the fork-head.
(i) Screw adjustment of adjustable props shall not be over extended.
(j) Double wedges shall be provided for adjustment of the form to the required position
wherever any settlement/ elastic shorting of props occurs. Wedges should be used only at
the bottom end of single prop. Wedges should not be too steep and one of the pair should
be tightened/ clamped down after adjustment to prevent shifting.
78
(k) No member shall be eccentric upon vertical member.
(l) The number of nuts and bolts shall be adequate.
(m) All provisions of the design and/or drawings shall be complied with.
(n) Cantilever supports shall be adequate.
(o) Props shall be directly under one another in multistage constructions as far as possible.
(p) Guy ropes or stays shall be tensioned properly.
(q) There shall be adequate provision for the movements and operation of vibrators and other
construction plant and equipment.
(r) Required camber shall be provided over long spans.
(s) Supports shall be adequate, and in plumb within the specified tolerances.
In the load path from formwork to ground, each contact surface can contribute to
settlement (or ‘take up movement’). Where the surfaces in contact have actual contact at
few points only on application of force movement between the surfaces can be significant.
Take up movement can be assumed as follows. (i) wooden to wooden (not smooth) 0.5
mm, (ii) wooden to steel 0.4 mm, (iii) steel to steel 0.3 mm, (iv) where surfaces are
planned by machine and are matched for surface-to-surface contact, the limits can be
halved. If total movement in a load path exceeds 3 mm, either redesign the formwork or
reduce movement during concreting operation by preloading.
3.1.6 CONCRETING:
3.1.6.1 Batching: -
To avoid confusion and error in batching, consideration should be given to using the
smallest practical number of different concrete mixed on any site or in any one plant. In
batching concrete, the quantity of both cement and aggregate shall be determined by
mass; admixture, if solid, by mass: liquid admixture may however be measured in volume
or mass: water shall be weighed or measured by volume in a calibrated tank (see also IS
4925).
Concrete produced in batch mixing plant or Ready-mixed concrete supplied by ready-

mixed concrete plant shall be preferred. For large and medium project sites the concrete
shall be sourced from ready-mixed concrete plants or from on site or off-site batching and
mixing plants (see IS 4926).
a) The grading of aggregate should be controlled by obtaining the coarse aggregate in

different sizes and blending them in the right proportions when required, the different
sizes being stocked in separate stock-piles. The material should be stock-piled preferably
few days before use and tested for sieve analysis, flakiness and silt content. The grading
of coarse and fine aggregate should be checked as frequently as possible, the frequency
for a given job being determined by the Engineer-in-Charge to ensure that the specified
grading and quality is maintained.
79
b) The accuracy of the measuring equipment shall be within ± 2 percent of the quantity of
cement and water being measured and within ± 3 percent of the quantity of aggregate,
admixtures being measured.
[these tolerances were for ordinary concrete say up to M20 & site mixing. For batch
mixing plants the tolerances are much tighter]
c) The grading type and proportion of aggregates shall be made by trial in such a way, so as
to obtain densest possible concrete. All ingredients of the concrete should be used by
mass only. [This method gives economical mix, but not cohesive, segregation potential
can be higher.] Grading and proportioning can be done by an established method, aimed
to achieve the desired characteristics in the concrete.
d) Volume batching may be allowed with specific permission of Engineer-in-Charge, only
where weigh-batching is not practicable and provided accurate proportioning in concrete
have earlier been established and the total concrete work involve is small (say below 10
m³). Allowance for bulkage shall be made in accordance with IS 2386 (Part 3). The mass
volume relationship should be checked as frequently as necessary, the frequency for the
given job being determined by Engineer-in-Charge to ensure that the specified grading is
maintained.
e) It is important to maintain the water cement ratio constant at its correct value as specified.
For this, determination of moisture contents in both fine and coarse aggregates shall be
made as frequently as possible, the frequency for a given job being determined by the
Engineer-in-Charge according to weather conditions. The amount of the added water shall
be adjusted to compensate for any observed variations in the moisture contents. For the
determination of moisture content in the aggregates, IS 2386 (Part 3) may be referred to.
To allow for the variation in mass for aggregate due to variations in their moisture content,
suitable adjustments in the masses of aggregates shall be made. In many cases additional
dose of plasticizer (as re-dosing) may be required to adjust the workability. For this during
mix proportioning a machine shall be kept for additional/ provisional dose of plasticizer.
3.1.6.2 Mixing: -
In case of concrete production done without Batching Plant, concrete shall be mixed in
mechanical batch type concrete mixers conforming to IS 1791 having minimum two
blades and fitted with power loader (lifting hopper type). Mixing performance of the
mixer shall be tested as per IS 4634. Half bag mixers and mixers without lifting hoppers
shall be used with permission of Engineer in Charge for mixing concrete in small
quantities and of low grade (<M15). In exceptional circumstances, such as mechanical
breakdown of mixer, work in remote areas or power breakdown and when the quantity of
concrete work is very small, hand mixing may be done with the specific prior permission
of the Engineer-in-Charge in writing subject to adding 10% extra cement. When hand
mixing is permitted, it shall be carried out on a water tight platform and care shall be
taken to ensure that mixing is continued until the concrete is uniform in colour and
consistency.
For guidance, the mixing time may be 2 to 3 minutes for tilting drum mixers, for
hydrophobic cement it may be taken as 21/2 to 4 minutes. If a specific chemical admixture
is added, the mixing time can be reduced marginally, and adopted accordingly. For a
given mix and a particular mixer the optimum time of mixing should be determined by
trials to arrive at uniform mix.
80
1 Batching Plant Mixing: -
a) A batching plant shall be arranged by the contractor at his own cost and it should comply
with provisions of IS 4925. (When total concrete to be produced in a contract is more
than 5000 m³). The plant shall be capable of accurate batching and mixing of the
following materials, the provision regarding material depending upon prior agreement
between the supplier and the purchaser:
i) Cement;
ii) Fine aggregate;
iii) Coarse aggregate in proportions and size as specified by the purchaser;
iv) Water; and
v) Dispensing arrangements for admixtures, such as, air entraining agents or water
reducing and set retarding agent or both as specified by the purchaser.
b) If so desired by the Engineer in Charge, the plant shall have suitable arrangements for
supplying concrete having its temperature as specified. In most cases arrangements are
required to add chilled water or ice flakes in the concrete in place if mixing water, and
arrangement for pre cooling of aggregates before mixing. The mixing plant should be
under a cover to avoid heat from sun. The actual details of the cooling or heating
arrangements shall be as agreed to between the Engineer in Charge and the Contractor.
(As per the weather).
c) For individual batchers the following tolerances shall apply, based on the required weight
of
the material being weighed: Percent
Cement and other cementitious materials ±1
Aggregates ±2
Water ±1
Admixture ±3
d) For cumulative batchers interlocked sequential controls shall be provided and the above
tolerances shall apply to the required cumulative weight of material as batched.
e) Arrangement for online printing of slips showing all the ingredients shall be made and
checked periodically by the Engineer in Charge.
f) For Large works where quantity of concrete is more than 25000 Cum, Supervisory Control
and Data Acquisition System (SCADA) must be deployed to Batching plant at
Contractors cost to acquire and store data from any place.
The SCADA System shall include-
1. The cost of procuring, establishing, running operating & maintaining SCADA

including necessary Software, all Sensors, and any other instrumentation / automation
required to acquire the desired test parameters.
2. The CTM used by the Contractor for this work shall be SCADA Software Enabled.
81
3. It shall provide Web connectivity on proper site where data is being acquired,
transmitted, processed, stored and retrieved with minimum speed of 1 MBPS and with
100 % uptime (Connectivity)
4. The Web Application thus provided shall be got approved by the Engineer-in-Charge.
It shall also provide an Agent Software for integrating with this Web Application.
5. The Web Application shall be enabled to communicate the Data which is beyond the
set parameters by SMS and e-mail to the representative of Engineer-in-Charge.
6. The Agency providing the Web Application shall cooperate with the Engineer in
Charge for providing all the necessary Data / Reports as and when necessary.
7. The Agency providing the Web Application shall make any changes/ medications in
the Web Applications as and when directed by Engineer in Charge.
8. Web-based application including Computer Software, Hardware etc. to transmit,

process, store and retrieve the data in the form and formats as prescribed by the
Engineer-in-Charge.
9. Arrangement for security of data, Disaster recovery arrangement during the

construction period and up to defect liability period. (DLP), shall be prevailing I.T.
Industry practice.
10. Calibration of all SCADA related attachment / accessories as per the latest prevailing
specification, Web based application to monitor the schedule of Calibration of all
SCADA related attachment / accessories. The invalidity of calibration shall lead to
non-acceptance of work or measurement and it shall not be paid for such non-accepted
work or measurement.
11. Submission of printed and authenticated reports to the Engineer-In-Charge as and

when required.
2 Power Loader Mixing:

Such mixer shall be used only for small quantities of concrete leaner than M15.
Mixer will be fitted with a power loader complying with the following requirements.
(a) The hopper shall be of adequate capacity to receive and discharge the maximum nominal
batch of unmixed materials without spillage under normal operating conditions on a level
site.
(b)The design of the loader shall be such that it allows the loading hopper to be elevated to
such a height that the centre line of the chute plate of the hopper when in discharge
position, is at an angle of not less than 50º to the horizontal. A mechanical device to aid
discharge of the contents as quickly as possible from the hopper to the drum may also be
provided. Even when a mechanical device is provided, it is recommended that the angle
of centre line of the chute plate of the hopper when in discharge position, should be as
large as practicable, preferably not less than 40º to horizontal.
(c) When the means of raising and lowering the loading hopper includes flexible wire ropes
winding on to a drum or drums, the method of fastening the wire to rope to the drums
82
shall be such as to avoid, as far as possible any tendency to cut the strands of the ropes
and the fastening should preferably be positioned clear of the barrel of the drum for
example, outside the drums flange. When the loading hopper is lowered to its normal
loading position, these should be at least one and a half drums of rope on the drum.
(d)Clutch brake and hydraulic control lever shall be designed so as to prevent displacement
by liberation or by accidental contact with any person.
(e) The clutch and brake control arrangements shall also be so designed that the operator can
control the falling speed of the loader.
(f) Safety device shall be provided to secure the hopper in raised position when not in use.
3 Machine Mixing without Batching Plant:

The mixer drum shall be flushed clean with water. Measured quantity of coarse aggregate
shall be placed first in the hopper. This shall be followed with measured quantity of fine
aggregate and then cement. In case fine aggregate is damp, half the required quantity of
coarse aggregate shall be placed in the hopper, followed by fine aggregate and cement.
Finally, the balance quantity of coarse aggregate shall be fed in the hopper, & then the
dry materials are slipped into the drum by raising the hopper. The dry material shall be
mixed for at least four turns of the drum. While the drum is rotating, water shall be added
gradually to achieve the water cement ratio as specified or as required by the Engineer-
in-Charge. After adding water, the mixing shall be continued until concrete of uniform
colour, uniformly distributed material and consistency is obtained. Mixing shall be done
for at least two minutes after adding water. If there is segregation after unloading from
the mixer, the concrete should be remixed. The drum shall be emptied before recharging.
When the mixer is closed down for the day or at any time exceeding 20 minutes, the drum
shall be flushed cleaned with water.
4 Mixing Efficiency:
The mixer shall be tested under normal working conditions in accordance with the method
specified in IS 4643 with a view to check its ability to mix the ingredients to obtain
concrete having uniformity within the prescribed limits. The uniformity of mixed
concrete shall be evaluated by finding the percentage variation in quantity (mass in water)
of cement, fine aggregate and coarse aggregate in a freshly mixed batch of concrete.
The percentage variation between the quantities of cement, fine aggregate and coarse
aggregates (as found by weighing in water) in the two halves of a batch and average of
the two halve of the batch shall not be more than the following limits:
Cement 8%
Fine aggregate 6%
Coarse aggregate 5%
5 Transportation and Handling:

Concrete shall be transported from the mixer to the place of laying as rapidly as possible
by methods which will prevent the segregation or loss of any of the ingredients and
maintaining the required workability.
During hot or cold weather, concrete shall be transported preferably in Transit Mixer,
other suitable methods to reduce the loss of water by evaporation in hot weather and heat
83
loss in cold weather may also be adopted. Harsh concrete (having slump less than 30 mm)
or dry lean concrete (suitable for roller compaction) can be transported in dumpers.
3.1.6.3 Placing of concrete: -

The placing of concrete shall generally be followed as per PWD Handbook chapter 40
titled “Placement of Concrete”. The concrete shall be deposited as nearly as practicable
in its final position to avoid re-handling. It shall be laid gently (not thrown) and shall be
thoroughly vibrated and compacted before setting commences and should not be
subsequently disturbed. Method of placing shall be such as to preclude segregation. Care
shall be taken to avoid displacement of reinforcement or movement of formwork and
damage due to rains. As a general guidance, the maximum free fall of concrete may be
taken as 1.5 m.
1 Procedure for Placing of Concrete:

1. Engineers Approval of Equipment and Methods: Before any concrete is placed, the
entire placing program, consisting of equipment, layout proposed procedures and
methods shall be submitted to Engineer-in-Charge and no concrete shall be of such
size and design to ensure a practically continuous flow of concrete during depositing
without segregation of materials, considering the size of the job and placement
location.
2. Time Interval between Mixing and Placing: Concrete shall be placed in its final
position before the cement reaches its initial set and concrete shall normally be
compacted in its final position within thirty minutes of leaving the mixer and once
compacted it shall not be disturbed.
3. Avoiding Segregation: Concrete shall in all the cases be deposited as nearly as

practicable directly in its final position and shall not be re-handled or caused to flow
in a manner which will cause segregation, loss of materials, displacement of
reinforcement, shuttering or embedded inserts or impair its strength. For locations
where direct placement is not possible, and in narrow forms, contractor shall provide
suitable prop and Elephant Trunks to confine the movement of concrete. Special care
shall be taken when concrete is dropped from a height, especially if reinforcement is
in the way, particularly in columns and thin walls.
4. Placing by Manual Labour: Except when otherwise approved by Engineer-in-Charge,

concrete shall be placed in the shuttering by shovels or other approved implements and
shall not be dropped from a height more than 1.5 m. or handle in a manner which will
cause segregation.
5. Placing by Mechanical Equipment: The following specifications shall apply when

placing of concrete by use of mechanical equipment is specially called for while
inviting bids or is warranted, considering the nature of work involved. The control of
placing shall begin at the mixer discharge. Concrete shall be discharged by a vertical
drop into the middle of the bucket of hopper and this principle of a vertical discharge
of concrete shall be adhered-to throughout all stages of delivery until the concrete
comes to rest in its final position.
84
Type of buckets: All concrete shall be conveyed from the mixer to the place of final
deposit in suitable buckets, containers which shall be leak-tight. All means of
conveyance shall be adopted for delivering concrete to the required consistency/
workability and plasticity without segregation. Central bottom dump buckets of a type
that provides for positive regulation of the amount and rate deposition of concrete in
all dumping position shall be employed.
Operation of Bucket: In placing concrete in large open areas, the bucket shall be
spotted directly over the position designated and then lowered for dumping. The open
bucket shall clear the concrete already in place and the height of drop shall not exceed
1.0 m. The bucket shall be opened slowly to avoid high vertical bounce. Dumping of
buckets on the swing or in any manner which results in separation of ingredients or
disturbance of previously placed concrete will not be permitted.
6. Placement in Restricted Forms: Concrete placed in restricted forms by borrows,

buggies, cars, short chutes or hand shoveling shall be subject to the requirement for
vertical delivery of limited height to avoid segregation and shall be deposited as nearly
as practicable in its final position.
7. Chuting: Where it is necessary to use transfer chutes, specific approval of Engineer-in-

Charge must be obtained to type, length, slopes, baffles, vertical terminal and timing
of operations. These shall be so arranged that almost continuous flow of concrete is
obtained at the discharge and without segregation. To allow for the loss of mortar
against the sides of the chutes, the first mixes shall have less coarse aggregate. During
cleaning of chutes, the wastewater shall be kept clear of the forms. The concrete shall
not be permitted to fall from the end of the chutes by more than 1.0 m. Chutes, when
approved for use, shall have slopes not flatter than 1 vertical to 3 horizontal and not
steeper than 1 vertical to 2 horizontal, chutes shall be of metal or metal line or PVC of
rounded cross section. The slopes of all chute sections shall be approximately same.
The discharge end of the chutes shall be maintained above the surfaces of the concrete
in the forms.
8. Placing by Pumping/ Pneumatic Placers: Concrete may be conveyed and placed by

mechanically operated equipment e.g., pumps or pneumatic placers, only with the
written permission of Engineer-in-Charge. The slump shall be held to the minimum,
necessary for conveying concrete by this method.
When pumping is adopted, before pumping of concrete is started, the pipelines shall
be lubricated with one or two batches of mortar composed of one part cement and two
parts sand. The concrete mix shall be specially designed to suit pumping. Care shall
be taken to avoid stoppages in work once pumping has started.
When pneumatic placer is used, the manufacturer’s advice on layout of pipeline shall
be followed to avoid blockages and excessive wear. Restraint shall be provided at the
discharge box to cater for the reaction at the end. Manufacturer’s advice shall be
followed regarding concrete quality and all other related matters when pumping/
pneumatic placing equipment are used.
85
9. Concrete in Layers: Concreting, once started, shall be continuous until the pour is
completed. Concrete shall be placed in successive horizontal layers of uniform
thickness up to 30 cm as directed by Engineer-in-Charge. These shall be placed as
rapidly as practicable to prevent the formation of cold joints or planes of weakness
between each succeeding layers within the pour. The thickness of each layer shall be
such that it can be deposited before the previous layer has set. The bucket loads or
other units of deposit, shall be spotted progressively along the face of the layer with
such overlap as will facilitate spreading the layer to uniform depth and texture with a
minimum of shoveling stones into mortar rather than mortar on to stones. Such a
condition shall be corrected by redesign of mixer other means, as directed by Engineer-
in-Charge. Green cutting / roughening of concrete in case of mass concreting in layers
shall be done for proper bonding.
10. Bedding of Layers: The top surface of each pour and bedding planes shall be
approximately horizontal unless otherwise instructed.
11. Provide shear keys in staggered form in sufficient numbers at the end of days work
when laying concrete in layers.
12. Placement of Concrete in Hot Weathering (IS 7861-Part I-1975) wherever Required.
a. Placement and Finishing- Forms, reinforcement, and sub grade shall be sprinkled
with cool water prior to placement of concrete, to keep wet and cool the surface on
which fresh concrete will be placed. It should be such that at the time of placing
fresh concrete, the base shall be surface dry but saturated. There shall be no free
water at anywhere on the surface. The area around the work shall be kept wet to the
extent possible to cool the surrounding air and increase its humidity, thereby
reducing temperature rise and evaporation from the concrete. When temperature
conditions are critical, concrete placement may be restricted to the evenings or night
when temperatures are lower and evaporation is less.
b. Higher speed of placement and finishing helps to minimize problems in hot weather
concreting. Delays contribute to loss of workability and lead to use of additional
mixing water to offset such loss. Ample personnel shall be employed to handle and
place concrete immediately on delivery. On flat work; all steps in finishing shall be
carried out promptly. Delays in finishing air-entrained concrete pavement in hot
weather may lead to formation of a rubbery surface which is impossible to finish
without leaving ridges that impair the riding qualities of pavement.
c. Concrete shall be placed in layers thin enough (say 200 to 300 mm) and in areas
small enough so that the time interval between consecutive placements is reduced
and vibration or other working of the concrete will ensure complete union of
adjacent portions. If cold joints tend to form or if surfaces set and dry too rapidly,
or if plastic shrinkage cracks tend to appear, the concrete shall be kept moist by
means of fog or mist sprays, wet burlap, cotton mats, or other means at very early
age as needed say 1 to 2 hours only. Fog sprays applied shortly after placement and
before finishing, have been found to be particularly effective in preventing plastic
shrinkage cracks when other means have failed. Alternately concrete surface should
be covered immediately by plastic sheet to avail evaporation loss and hence plastic
shrinkage cracks.
86
d. All placement procedures shall be directed to keep the concrete as cool as
practicable and to ensure its setting and hardening under temperature conditions
which are reasonably uniform and, under moisture conditions, which will minimize
drying. Concrete, whether delivered by a truck or otherwise, shall reach the forms
at a temperature not higher than 35 ºC and whatever is practicable shall be done to
minimize temperature increase during placing, consolidation, finishing, and curing
operations.
e. If contract specifications specify the temperature of the concrete at the time of
placement, it should be the temperature immediately after compaction and
finishing. In many cases such specified temperature may be 30ºC.
13. CONCRETING AT NIGHT TIME: If concrete is to be placed at night adequate

lighting arrangements shall be made, as directed by the Engineer-in-charge.
14. CONCRETING DURING RAINS: When concreting is required to be done or

continued while it shall be seen that the concrete is not damaged due to rain while it is
being transported and placed. After placing the green concrete, it shall be adequately
covered for a period of 24 hours when it will be capable for being cured by splash of
water. The surface of fresh concrete should be maintained on a slope sufficient for
result in the self drainage of the rain water. The work shall however be discontinued
when the rain is so severe that water collects in pools or washes the surface of the fresh
concrete and it is not possible to provide adequate shelter.
3.1.6.4 Compaction: -
Concrete shall be thoroughly compacted and fully worked around embedded fixtures and
into corners of the formwork. Compaction shall be done by mechanical vibrator of
appropriate type, till a dense concrete is obtained. The mechanical vibrators shall conform
to IS 2505, IS 2506, IS 2514 and IS 4656. To prevent segregation, over vibration shall be
avoided. Compaction shall be completed before the initial setting time of concrete. For
the items where mechanical vibrators are not to be used, the contractor shall take
permission of the Engineer-in-Charge in writing before the start of the work, however
other method of compaction shall be used to properly compact the concrete. After
compaction the top surface shall be finished even and smooth with wooden trowel before
the concrete begins to set.
3.1.6.5 Construction Joints: -

Concreting shall be carried out continuously up to construction joints. The position and
arrangement of construction joints shall be as shown in the structural drawings or as
directed by the Engineer-in-Charge. Number of such joints shall be kept minimum. Joints
shall be kept as straight as possible. Construction joints should comply with IS 11817.
3.1.6.6 Where the work has to be resumed on a surface which has hardened, such surface shall
be roughened. This roughening can be done before the concrete has set. Or alternately
after the concrete has set, it should be ensured that the process of roughening does not
disturb or loosened the aggregate-mortar bond in concrete. It shall then be swept clean
and thoroughly wetted. For vertical joints, neat cement slurry, of workable consistency
by using 2 kgs of cement per sqm shall be applied on the surface before it gets dry.
87
For horizontal joints, the surface shall be covered with a layer of mortar about 10-15 mm
thick composed of cement and sand in the same ratio as the cement and sand in concrete
mix. This layer of cement slurry of mortar shall be freshly mixed and applied immediately
before placing of the concrete.
3.1.6.7 Where the concrete has not fully hardened, all laitance shall be removed by scrubbing
the wet surface with wire or bristle brushes, and should be cleaned thoroughly with air-
water jet. Care being taken to avoid dislodgement of particles of coarse aggregate. The
surface shall be thoroughly wetted and all free water removed. The surface shall then be
coated with neat cement slurry @ 2 kgs of cement per sqm. On this surface, a layer of
concrete not exceeding 150 mm in thickness shall first be placed and shall be well rammed
against old work particular attention being paid to corners and close spots; work,
thereafter, shall proceed in the normal way.
3.1.6.8 Curing: -
Concrete shall be kept continuously moist for not less than 14 days and may be extended
up to 21 days as directed by engineer-in-charge depending upon the season. Construction
joints shall be cured in the same way as other concrete. Approximately horizontal surfaces
shall be cured by use of wet quilts or mats. Vertical surfaces shall be cured by covering
with wet jute or hessian cloth. However, preferably mechanical arrangement for
continuous curing shall be made. If the curing arrangement of the contractor is not
satisfactory, the Engineer in Charge may in his discretion engage labour and provide
material and equipment for curing and recover expenditure thus involved from the
contractor. On site curing register shall be maintained by the contractor.
3.1.7 TESTING OF CONCRETE: -

The Quality Control Tests to be conducted are categorized as below. The tests shall be
done as per provisions of relevant IS codes as mentioned along with.
3.1.7.1 Tests conducted prior to construction

Table 12
Sr Name of IS Code for

Name of Test Testing Frequency
No. Material/Work Testing
1 Cement a) Setting Time One test for 100 tonne of (IS:4031Part
cement per supply batch of 5)
same grade & same
manufacturer.
One test for 100 tonnes of (IS:4031Part
b) Compressive 6)
cement (same brand &
strength of cement
grade)
by mortar cube
2 Coarse a) Gradation for one sample for each quarry IS 383
Aggregates PCC or RCC source/Once in a week/
works (sieve every day-do – every week.
analysis If in doubt
b) Flakiness index Once for each source of (IS:2386
supply part 1)
88
Sr Name of IS Code for
Name of Test Testing Frequency
No. Material/Work Testing
c)Deleterious One test per source of (IS:2386 part
constituents supply 2)
d)Water (IS:2386
absorption/content part 3)
e) Aggregate - do – (IS:2386 part
Impact value If in doubt one test at 4)
f) Soundness [if approved test house
water absorption (IS:2386 part
exceeds 2%] 5)
g) Alkali Silica (IS:2386
reactivity part 7)
3 Fine a) Gradation One sample for each quarry (IS:2386
Aggregates source / Once in a week part 1)
If in doubt, one test IS:2386 -part
b) Deleterious If in doubt, one test 2)
Constituents (IS:2386 -
c) Alkali silicate part 7)
reactivity
4 Water Normally potable For large works If the IS:3025(Part
water is good quality is in doubt Samples 17)
enough for taken from each source, IS:3025(Part
making concrete each season and tested at an 16)
Determination of approved test house IS:3025(Part
Impurities - Suspended matter 19)
- Organic IS:3025(Part
- Inorganic 24)
- Sulphates (as SO3) IS:3025(Part
- Chlorides (as Cl) 32)
5 Concrete Concrete Mix 1) One at the start of Every IS 10262
Design Season
2) Additional Mix Design
if source of any ingredient
is changed
3)Quality system indicate
increase of standard
deviation from the value
taken in mix proportioning
or problems in acceptance
criteria
6 Chemical a) Dry Material One test at the time of Mix IS 9103
Admixtures Content Design.
b) Ash Content Manufacturer’s certificate
c) Relative for each supply.
Density
d) Chloride Ion
Content
e) pH
89
3.1.7.2 Quality Control Tests at the time of Construction
Table 13
Name of IS Code for

Sr No Name of Test Frequency of Testing
Material/Work Testing
1 Fine and Coarse a) Moisture Once before commencement (IS:2386part
Aggregates content of work – each day and after 3)
b) Silt Content every 4 hours thereafter
2 Concrete a) Workability 1 test per every 2 hrs per mixer (IS:1199)
– slump cone Qty No. of
test (Cum) Tests per
b) Cube (IS:516)
day
Strength 1-5 1
6-15 2
16-30 3
31-50 4
>51 4+1 for
additional
50 Cum
3 Concrete for a) Cube One sample per 380 Cum qty (IS:516)
Massive Strength for PCC and per 190 cum for
Structures [ reduce m³ qty] RCC per batching plant per
shift (IS:1199)
1 test per every 2 hrs per mixer
b) Workability
– slump cone
test/vee- (IS:516)
bee/flow etc
c) Core Test
b) One core test for each grade for

initial 500 cum qty in one
working season. After
satisfactory results thereafter
one test for every 3000 cum
4 Chemical a) Dry Material One test for every 9000 liters of IS 9103
Admixtures Content admixture
b) Ash Content
c) Relative
Density
d) Chloride Ion
Content
e) pH
Note: RCPT values are important indicators in RCC.
90
If the variations in quality are expected or found to be higher, the testing will be more
frequent than indicated above.
3.1.7.3 Quality Control Tests after Construction

1 Non-destructive Tests (IS 13311)
When the 28 days compressive strength values on field samples are doubtful or not
acceptable, the contractor has an option to propose to test the concrete by non-destruction
test method at his cost, if concrete work done is otherwise not of bad quality. In such case
Engineer-in-Charge shall arrange non-destruction tests at the appropriate places on the
structure. Such tests may be any one or a combination of the following A) and B)
depending up on severity of the problems.
A)
i.Rebound hammer test

ii.Windsor Penetration Probe test
iii.Pulse velocity (sonic or Ultrasonic) test
B)
iv.Core test
v.Load test
(a) Interpretation of rebound hammer, Windsor Probe and Pulse velocity test results shall
rest with the Engineer-in-Charge.
(b) Core test, if ordered by the Engineer-in-Charge, shall be done in accordance with IS 516.
Samples for such test shall be taken from locations to be identified by the Engineer-in-
Charge and such samples shall be collected in compliance with IS: 1199.
(c) If felt necessary, the Engineer-in-Charge may instruct load testing for any part of the
structure based on doubtful concrete strengths. Such test shall be carried out as per details
to be provided by the Engineer-in-Charge in consultation with the structural consultants.
(d) Engineer-in-Charge shall alone decide where such tests are to be conducted. He may
instruct tests to be conducted at laboratories other than the field laboratory and such
instructions shall be followed without claiming extra charges on this account.
2 Laboratory Facilities
(1) The Concrete Manufacturer/ Placement contractor shall set up a laboratory at this own
expense which shall have facilities, for conducting all necessary field test on materials
and field and laboratory test on concrete. The laboratory shall be staffed by the concrete
Manufacturer/ Placement Contractor with qualified and experienced scientists and
technicians.
(2) All test conducted at the field laboratory shall be carried out by qualified and trained
technicians employed by the concrete manufacturer/ concrete placement contractor, in
presence of authorized representative of the Engineer-in-Charge. All test reports and
observation reports shall be jointly signed by the Engineer-in-Charge authorized
representative and the technician conducting such test.
91
(3) The concrete manufacturer/ concrete placement contractor shall arrange for all tests to
be conducted in accordance with these specifications, including all necessary tools,
plants, equipment and material, and shall be responsible for conducting all test at his cost.
3.1.8 ACCEPTANCE CRITERIA

3.1.8.1 Compressive Strength: The concrete shall be deemed to comply with the strength
requirements when both the following conditions are met:
(a) The mean strength determined from any group of four consecutive test results complies
with the appropriate limits in column 2 of Table 12.
Any individual test result complies with the appropriate limits in col. 3 of Table 12.
Table 12
Characteristic Compressive Strength Compliance Requirement
Specified Mean of the Group of 4 Non-Overlapping Individual Test Result

Grade Consecutive Test Results in N/mm2 in N/mm2
(1) (2) (3)
M15 ≥fck+ 0.825 × established standard deviation

(rounded off to nearest 0.5 N/mm2),
Or fck + 3.0 N/mm2, ≥fck- 3 N/mm2

and
Whichever is latest edition and amendments of IS
above greater
Notes 1) In the absence of established value of standard deviation, the values given in
table 8 of IS 456 may be assumed, and attempt should be made to obtain results of 30
samples as early as possible to establish the value of standard deviation. [SD should be
taken as in mix design exercise, if higher than that in table 8 of IS 456.]
2) fck = characteristic compressive strength specified for the corresponding grade while
tested on 15 × 15 × 15 cm cube.
92
The sample of application of acceptance criteria is given in table below for concrete of
grade M15 having standard deviation less than 3.64 MPa
Compressive Mean of Comments about acceptance

strength of strength of 4
Sample
Date sample (Average consecutive non
No.
of 3 specimen) in overlapping
MPa samples in MPa [ 1 MPa = 1 N/mm² ]
1 1 Jan 15 13 All the individual samples are

above fck-3 MPa (15-3=12)
2 1 Jan 15 22 and the mean is above fck+3
18.25
3 2 Jan 15 17 MPa (15+3=18) all the 4
samples are acceptable.
4 2 Jan 15 21
5 2 Jan 15 17 All the individual samples are

above fck-3 but the mean is
6 2 Jan 15 19 below fck+3, hence all the 4
17.75
7 2 Jan 15 18 samples have failed.
8 2 Jan 15 17
Note: 1) The criteria shall be applied separately for each type of concrete mix e.g., separately
for M15 (20 MSA), M15 (80 MSA), M25 (40 MSA).
2) The criteria shall be applied separately for each batching plant and each work.
[When 5th result has come, take result no. 2, 3, 4 & 5, average is 19.25, hence 5th passes.
When 6th result has come, take result no. 3, 4, 5 & 6, average is 18.50, hence 6th passes.
When 7th result has come, take result no. 4, 5, 6 & 7, average is 18.75, hence 7th passes.
When 8th result has come, take result no. 5, 6, 7 & 8, average is 17.75, hence 8th does not
pass and indicate that standard deviation is high, and concrete in field representing field
samples 5 to 8 need to be evaluated and also review the SD for mix design.
Above is hypothetical case, much away from reality. Strength varies from 13 to 22 which
is very wide variation, that represents a bad quality. For such a bad quality regime, no
acceptance criteria can work.
3.1.8.2 Flexural Strength: When both the following conditions are met, the concrete complies
with the specified flexural strength.
(a) The mean strength determined from any group of four consecutive test results exceeds
the specified characteristic strength by at least 0.3 N/mm2
(b) The strength determined from any test result is not less than the specified characteristic
strength less 0.3 N/mm2.
93
3.1.8.3 Concrete is liable to be rejected if it is porous or honey-combed, its placing has been
interrupted without providing a proper construction joint, the reinforcement has been
displaced beyond the tolerances specified, or construction tolerances have not been met.
However, the hardened concrete may be accepted after carrying out suitable remedial
measures to the satisfaction of the Engineer-in Charge as per provisions of IS 456-2000.
3.1.9 MODE OF MEASUREMENT:

Concrete item shall be measured and paid on cubic meter basis.
It shall be the net quantity of concrete after deducting quantities for opening. No
deduction shall be made for anchor bars, reinforcement, grout holes bores or weep holes
or any opening not exceeding 100 sq.cm. in cross section.
Measurements of concrete shall be taken within the specified pay lines for the structure
or as indicated on the working drawings. Any concrete placed beyond the pay line or
deviated from drawing is not payable.
The quantity of item shall be computed by using prismoidal formula for which the
intervals thereof shall be decided by Engineer-in-charge wherever applicable as per site
conditions.
3.1.10 MODE OF PAYMENT:

Block outs and slots whenever necessary for embedment in the form of foundation bolt
and other parts, shall be provided by the contractor without any extra cost. The payment
for formwork required for concrete if any, shall be presumed to be included in rate of
concrete item.
The Contractor shall submit the report covering all tests on material, workmanship, finally
laid concrete at required frequencies (The tests prior to construction (3.14.1), the tests at
the time of construction (3.14.2) and tests after construction (3.14.3) defined in relevant
paragraphs.).
If the Engineer-in-Charge of work found that contractor is using sand dust instead of
crushed / manufactured sand, penalty will be charged to the contractor and no payment
will be given for the concrete work done by using material from that plant.
No extra payment for using Artificial/ V.S.I crushed sand.
If extra quantity of cement consumed in mixed design by the use of crushed / artificial
sand, no extra payment will be given to the contractor.
It should also cover the analysis of the tests and the conclusion for the acceptance as per
IS-456.
Measurement shall be recorded after satisfactory report. The Engineer-in-Charge will be

responsible to verify and accept the report before accepting the measurements.
The quantity measured shall be paid only after removal of shuttering and curing the
concrete for specified period etc all complete.
94
Percentage of
Sr. No. Item
Payment
1 Running Account Bill 90%
Measurements of work done for the final with satisfactory

performance test
2 100%
&
At the time of measurement for Final.
3.1.11 LIST OF INDIAN STANDARD CODES:

Sr. No. I.S. Code Description
ORDINARY PORTLAND CEMENT,33 GRADE

1 269
SPECIFICATION
Coarse and fine aggregates from natural sources for

2 383-2016
Concrete
4 455 PORTLAND SLAG CEMENT-SPECIFICATION
5 456 Code of practice for plain and reinforced concrete
6 457 Mass Concrete
7 516 Method of test for strength of concrete
8 1199 Method of sampling and analysis of concrete
9 1200(Part ΙI) Method of measurement of cement of concrete work
10 1322 Bitumen felts for water proofing and damp proofing
PORTLAND-POZZOLANA CEMENT
11 1489 Part- 1&2
SPECIPICATION
Code of practice for application of cement lime plaster

12 1661(Part ΙI)
finishes
13 1791 General requirements of batch type of Concrete mixers.
2386 Part 1-8 Method of test for Aggregate for concrete
14 2505 Concrete vibrators
15 2506 Screed Board Vibrators
95
16 2645 Specification for integral water proofing compound
Specification for cinder aggregate for use in lime

17 2686
concrete
18 3535 Method of sampling of cement
3812 & its Part 1-

Fly ash
3
19 4031 Part 1-6 Methods of physical test of cement
20 4082 Stacking & Storage of Construction Material
BATCH-TYPE CONCRETE MIXERS - METHOD OF

21 4634
TEST-PERFORMANCE
22 4656 Specification for form vibrators
23 4925 Ready mix concrete
24 4926 Batching Plant
25 6491 Methods of sampling Fly Ash
26 7861(Part Ι) Hot weather concreting
27 7861(Part ΙΙ) Cold weather concreting
28 9103 Admixture for concrete
29 10262 Concrete mix design
30 11817 Construction joints
31 13311 Non destructive testing
32 14687 False work for concrete structures- Guide line
96
3.1.12 REGISTERS TO BE MAINTAINED
Formats for Field work
1 Cement Register
Sr. No Date Mfg. Detail Quantity No of Samples Results Lab Ref Signature with name & Designation
3 days 7 days 28 days Maintained by Checked by
1 2 3 4 5 6 7 8 9 10 11
2 Sand (A)
Sr. No. Date Time Sample Location /Type Silt % Signature with name & Designation
1 2 3 4 5 7 8
2 Sand (B)
Signature with name & Designation
Sr. No Date Time Sample Location /Type Bulkage
1 2 3 4 5 7 8
97
2 Sand (C)
Sr. Signature with name

Sieve Analysis
No Sieve & Designation
Location
Date I.S. Wt. % wt Cumulative % Analysis
/Type As per I.S. 383 - 1970-T-4/P-11 Std Maintained Checked
Size in retained retained Wt passing - FM
%age passing for sand grading zone by by
mm in gm Retained
1 2 3 4 5 6 7 8 9 10 11 12 13 15 16
I II III IV
90 - 95 -
4.75 90 - 100 90 - 100 100 100
85 - 95 -
2.36 60 - 95 75 -100 100 100
75 - 90 -
1.18 30 - 70 55 - 90 100 100
80 -
600 15 - 34 35 - 59 60 - 79 100
15 -
300 5 - 20 8 - 30 12 -40 50
150 0 - 10 0 - 10 0 - 10 0 - 10
75 For crushed sand limit increased to

20% The total amount of grading
-75 outside the limit
Total
98
2 Coarse aggregate A
Sieve Analysis As per Mix Design
MS Designation
Sr. No Date Location
A Maintained Checked By
40 20 10 4.75 40 20 10 4.75 by
1 2 3 4 5 6 7 8 9 10 11 12 13 14
3 Coarse aggregate B
Impact Signature with name & Designation
Flakiness Abrasion Crushing
Sr. No Date Locations value Alkali Aggregate
index value test value test Maintained by Checked by
test
1 2 3 4 5 6 7 8 9 10
4 Concrete Placement Register

Concrete As per Mix design /Tender Specification Remark
Mix MSA Cement W/C ratio Sand Coarse Aggregate Water Admixture
80 40 20 10
99
Per Load
Design Cement Used Sand C.A

Sr. Component Sample W/C
Date Mix MSA Detail Quantity 40 20 10 Admixture
No / Location Identification Ratio
per Load Weight
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Mode of Type of vibrator / Slump No of Strength Signature with name &

mixing mode of compaction Every 2 Cubes Designation
Hours Casted
7 days 28 days Lab. Ref. Maintained by Checked by
15 16 17 18 19 20 21 22 23
100
5 Load Register
Sr. Location of Mixer Date Time (Hours) No of Loads Average Signature with name &
No Cycle time Designation
Minutes
From to Maintained by Checked by
1 2 3 4 5 6 7 8 9
6 Mortar / Colgrout
Strength (On CTM)
Loads / Hr Signature with name
Date No of (Obtained after
Sr. Sample Component Tachometer (As per & Designation
& Mix Flow Cubes testing in Lab.)
No. Identification / Location Reading Load
Time Casted 7 28 Lab Maintained Checked
Register)
days days Ref. by by
1 2 3 4 5 6 7 8 9 10 11 12 13 14
7 Stone

Sr. Sample Identification/ Quarry Water Specific Crushing Lab Designation
Date
No. Component Location Source Absorption Gravity Strength Ref. Maintained
Checked by
by
1 2 3 4 5 6 7 8 9 10
101
7 Steel Reinforcement
Sr. Date Sample Identification/ Type & Size Test result Signature with name & Designation
No. Component/ Location grade
Tensile Elongation Lab Maintained by Checked by
Strength /Ref
1 2 3 4 5 6 7 8 9 10
9 Field Test Earth Work

Signature with name
& Designation
Sr.
No.
Date Quarry Sample Location PMC NMC PDD ODD DDD=PDD/ODD
& Location
Time Maintained Checked
Chainage Offset R.L
by by
1 2 3 4 5 6 7 8 9 10 11 12 13
102
10 Field Register for proctor density Test
Sr. No Date Sample Identification Source Quarry ODD OMC Signature with name & Designation
No Location
1 2 3 4 5 6 7 8 9
Method of construction / formwork is used or specify the work method
Weight of
Sample Location
Sand + Weight of Sand Weight Weight of wet
Date & Location Weight of
Sr. No. Cylinder + Cylinder after of sand soil (Sand)
Time of Quarry Ch. Offset R.L. sand in pit
before pouring in cone from pit
pouring
1 2 3 4 5 6 7 8 9 10 11
103
3.2 PROVIDING & LAYING UCR MASONRY AND CHIP MASONRY
BACK FILLING (Item No. CC 11 and CC 8)

Providing & laying chip masonry back filling behind concrete lining in CM 1:8
including striking joints, curing, scaffolding etc. complete but excluding pointing etc.
complete as directed (35% mortar) (Cement 1.25 bags/Cum
3.2.2 SCOPE OF WORK:

The work covers furnishing all materials, equipments and labour for providing and
laying masonry in foundation or superstructure with or without face work, curing
and performing all the functions necessary and ancillary thereto etc. all complete.
3.2.3 MATERIAL:
3.2.3.1 STONE
1. QUALITY OF STONE
All stones used on the works under these specifications shall be obtained from
contractor’s own quarries approved by the Engineer in Charge. Approval to the
quarry will not mean that any stone from the quarry is approved. The stones to be
used in the masonry shall be tough, hard, sound and durable, resistant to weathering
action reasonably fine grained, uniform in colour& texture & free from seams, cracks
other defects which would adversely affect their strength, durability or appearance.
They shall also be free from weathered portion & skin.
2. SIZE:
The dimension of the stone to be used shall not be less than 23 cm. on any face.
Stones used shall not weigh less than 35 Kg. each. Chips however will be used to
make the masonry as dense as possible. The total volume of chips shall be limited to
5 to 10 % of masonry.
3. TEST FOR GOOD STONES:

• Before any quarry for a stone is approved, it shall be seen that besides satisfying the
specification mentioned, the stone shall be such as will not absorb water more than
5% of its weight after keeping it under water for 24 hours.
• It shall not have crushing strength less than 90% that of in dry condition.
3.2.3.2 SAND:
1. SOURCE AND SIZE:

The sand used for mortar shall be natural river sand or manufactured sand. The
maximum size shall be limited to 4.75 mm.
2. QUALITY:
The sand shall consist of hard, dense, durable uncoated gritty material, obtained
104
from rock fragments. It shall be free from injurious amounts of dust, lumps, soft
and flaky particles, shale, alkali, organic matter, loam mica and other deleterious
substances. The maximum percentage of deleterious matter of sand as delivered
for use in mortar shall not exceed the following values.
Deleterious Matter PERCENTAGE BY

WEIGHT
1 Materials passing 75-micron I.S. Sieve 3 Percent
2 Shale 1 Percent
3 Coal 1 Percent
4 Clay lumps 1 Percent
5 Total of other deleterious substances such
as Alkali, mica, coated grains, soft and 2 Percent
flaky particles
• The sum of percentage of all deleterious substances shall not exceed 5% by

weight. The sand shall be free from injurious amounts of organic impurities.
• Sand producing acolour darker than the standard in the colorimetric tests for
organic impurities shall be rejected.
• If the impurities are beyond the acceptable limits stated above, the sand shall
be washed with power/diesel driven sand washing machine to the entire
satisfaction of the Engineer-in-charge at the cost of the Contractor.
3 MECHANICAL ANALYSIS:
The natural sand shall be well graded and the sieve analysis of the sand shall
confirm to the following limits of gradation.
ASTM sieve No. Equivalent I.S.S. No. Cumulative percentage by
weight retained on Sieve
3/8" mesh 10.00 mm. Nil
4 mesh 04.75 mm. 1 to 8
8 mesh 02.36 mm. 10 to 25
16 mesh 01.18 mm. 25 to 45
30 mesh 600 microns 50 to 70
The gradation curve of the natural sand shall lie within the enveloping curve of
gradation specified as above.
4 A) FINENESS MODULUS:
• The fineness modulus shall be computed by adding cumulative percentages of
sand retained on the 6 standard sieves from No. 4 to No. 100 both inclusive
A.S.T.M. standard (or 4.75 mm., 2.36 mm., 1.18 mm. 600 microns, 300
microns, and 150 microns of the ISI specification) and dividing the sum by
105
100.
• Any deviation from the specified range of gradation and fineness modulus
shall not be permitted without the written permission of the Engineer-in-
charge.
• Corrective measures if any required for improving the fineness modulus shall
be arranged by the Contractor at his own cost as directed by the Engineer-in-
charge.
B) NATURAL SAND:
Natural sand shall have a fineness modulus ranging from 2.60 to 3.85 without
any admixtures.
C) ALLOWANCE FOR BULKAGE:

• If the sand as obtained from quarry or after its washing is found to be moist,
bulkage will be measured and allowance provided.
• Sand is stacked at site at least for 48 hours before use. Bulkage of such stack
will be measured regularly as directed by the Engineer-in-charge and allowed
according to these observations.
• Observations for bulkage will be made as per Indian Standards procedure and
allowance will be made as under:
Bulkage observed Allowance to be made
Below 5% NH
5 to 10 5 percent
10 to 15 10 Percent
15 to 20 15 Percent
20 to 25 20 Percent
25 to 30 25 Percent
30 to 35 30 Percent
3.2.3.3 CEMENT:
Cement used shall be any of the following and the type selected as per the contract
conditions, specifications and drawings.
The cement will be procured in standard bags as received from the

manufacturers and is expected to conform with the specifications, laid
down by Bureau of Indian Standards. The volume of one undamaged bag
shall be considered as 0.034 cubic meter.
106
3.2.3.4 WATER:
1 QUALITY:
Water used for making mortar shall be reasonably clean and free from
objectionable quantities of silt, organic matter, alkali, salts and other injurious
materials.
2 TURBIDITY PERMISSIBLE:
The turbidity of water for mixing mortar not be more than 2,000 parts per
million and shall preferably be as low as possible.
3.2.3.5 MORTAR-GENERAL:
1 SPECIFICATION FOR INGREDIENTS:

It shall be seen that the ingredients going to form the finished product of mortar
comply individually with the specifications separately laid out for each of them.
2 TIME FOR USE:

Mortar shall be used in masonry within the time specified for the initial set of
cement which shall not be more than 30 minutes as directed by the Engineer -
in-charge.
3 PROPORTION OF INGREDIENTS:
The proportions of ingredients mentioned in the detailed specifications for each
type of mortar are nominal proportions. The mix proportion is liable to be varied
at the discretion of the Engineer-in-charge to ensure the requisite strength. If
the nominal mix fails to give the requisite strength, the mix shall be varied as
directed by the Engineer-in-charge. The mix proportions stipulated are by
volume. The volume of sand will be directly measured prior to mixing. Volume
of cement shall be reckoned on the basis of 0.034 cum of cement per bag.
4 STIPULATED CRUSHING STRENGTH:
4.1 The stipulated crushing strength of various mortar proportions shall be as below.
Mortar mix Cement: Sand Stipulated crushing strength at the

end of 28 days kg/cm 2
1 1: 5 56
2 1: 6 35
3 1: 8 24
• The crushing strength of mortar used in part of Masonry shall not be less
than 80% of the final crushing strength, at the end of 28 days.
• In some cases, there is appreciable gain in strength beyond 28 days also. In

such cases if the strength is attained after 45 to 90 days, the masonry shall
be accepted as satisfactory.
107
4.2 PRELIMINARY LABORATORY TESTS:
Preliminary tests on cubes should be carried out in the laboratory well in advance
of commencement of work.
4.3 a) WORKS TESTS ON MORTAR:

Tests for crushing strength shall be on standard cubes as per relevant Indian
Standard Specifications. For works tests samples shall be taken on the job as and
when directed. Generally, for works test, samples shall be taken for every
100 cum. of masonry and at least once in a day. Materials for the works test
(Mortar, cement, sand as the case may be) shall be supplied by the Contractor
free of cost and collection of samples, casting of cubes, curing and testing
shall be carried out by the Corporation at its own cost.
4.3b) STANDARD OF ACCEPTANCE:

• Not a single sample of work test cubes shall have at the age of 28 days, a
crushing strength less than the stipulated crushing strength of mortar.
• Each sample of work test cubes shall assume to represent 100 cum masonry
and corresponding quantity of masonry showing crushing strength.
• If the crushing strength falls below acceptable limit of the stipulated crushing
strength, then the quantity of masonry represented by these samples will not
be paid for. Defective parts, if noticed shall be removed and redone by the
contractor at his cost.
3.2.3.6 CEMENT MORTAR:
1 PROPORTION:
The mortar shall be obtained by thoroughly mixing together the ingredients in a
mechanically operated mixer.
2 MODE OF MIXING:
• The ingredients of mortar shall be properly mixed in mixers as designed, so as
to positively ensure uniform distribution of all the component material
throughout the mass at the end of mixing period.
• After all materials except for the full amount of water in the mixer the mixing
of each batch shall continue for about 1 to 2 minutes depending upon the
revolutions per minutes of the mixer, and experience.
• The minimum mixing period specified above assumes proper control of the speed
of rotation of the introduction of the materials including water.
• The mixing time shall be increased at the discretion of the Engineer-in-
charge when the charging operation fails to produce the required uniformity of
composition and consistency within the batch and from batch to batch.
• The Contractor shall not be entitled for any extra payment of such increase in
mixing time.
• The excessive mixing requiring the addition of water to preserve the required
mortar consistency shall be avoided. If the mixing and charging operations are
such that required uniformity of mortar is obtained in shorter mixing time than
108
the minimum specified, without sacrifice of needed workability the mixing
time may be shortened under orders of the Engineer-in-charge.
• Mixing shall be done by mechanical means only.
• The sequence of feeding of the ingredients into the mixer shall generally be
as under :50% of requirement of water. 50% of requirement of sand. Full
quantity of cement. Balance quantity of sand. Balance quantity of water.
3.2.4 MIX VARIATION:

3.2.4.1 MIX VARIATION CLAUSE FOR CEMENT:
Mix variation (cement: sand) shall not constitute an extra item. If the
proportion of cement to sand is varied, an addition or deduction shall be made
in the rate of masonry for the cement used in excess or short of the stipulated
requirement of cement per cubic meter of masonry as shown in table below. For
this purpose, the volume of mortar in masonry shall be taken as shown in column
3 of table below corresponding to proportions of mortar and the volume of
mortar will be taken to be equal to the volume of the sand before mixing.
% of volume of mortar in Assumed cement content
Sr. No. Proportion of mortar
masonry in Kg. per cum.
1 C.M.--- 1: 8 35 62.5
2 C.M.--- 1: 6 35 83.5
45 107.0
35 100.0
3 C.M.--- 1: 5
45 128.5
3.2.5 MASONRY (GENERAL):

3.2.5.1 The clause under this section shall apply to all types of masonry.
3.2.5.2 STONES TO BE WETTED BEFORE USE:
• All stones, chips etc. shall be clean and free from dust or mud to ensure a good
bond with mortar and shall be wetted before being laid. For this purpose, the
stones that are immediately to be used shall be kept sprinkled with good clean
water.
• There shall be a good collection of stones and spauls within easy reach of
masonry to enable proper selection of stone for the individual locations while
laying, and the stones shall be kept continuously replenished.
3.2.5.3 DRESSING OF STONE:

• The stones shall be set in the work as received from quarry after early
knocking of weak corners and edges with a mason's hammer and after cleaning
scales of foreign matter if any.
3.2.5.4 LAYING:
• The stones shall be laid carefully on their natural flat bed so as to break
joints as much as possible.
• They shall be solidly embedded in mortar with close joints. No joints shall
109
exceed 4 cm. nor shall it be less than 12 mm. in the thickness.
• Chips of stones and spalls shall be wedged in the work wherever necessary to
avoid thick beds of joints of mortar and to give masonry maximum density.
• No dry work or hollow space shall be allowed.
• Every stone, whether large or small shall be set flush in mortar, shaken a nd
hammered down by a mallet to sink into it.
• The smaller stones used in the filling shall be carefully selected to fit snuggly
into the interstices between larger ones.
• Mortar to be added to fill the intervening spaces shall be well worked out by
trowel and steel bar.
• Disturbing the mortar during the period of setting shall be avoided. Mortar
joints of top and sides of a layer shall be pressed and brushed over by coir brush
as soon as masonry is laid so as not to leave any loose mortar.
3.2.5.5 (A) BONDING AND BOND STONES:

• For ensuring good bond, masonry shall be finished uneven at the end of the
day's work or at the top surface of the work done in each lift.
• No mortar shall be allowed to remain over the masonry at its top. At the
close of the day's work, all mortar on the top shall be removed.
• Bond stone shall be at least 0.05 Sq. m. face area and shall run back in the
work, at least 60 cm. or the full depth of the work if it is less than 60 cm.
• If the wall be over 60 cm. thick a line of headers overlapping each other at
least 15 cm. shall be laid right through the wall.
A row of vertical headers shall be erected at above 2 m. c/ c bothways so that
there is at least one vertical header for every 4 sq. m. in ever y layer. The
headers shall be at least 60 cm. long.
3.2.5.6 PRECAUTIONS TO OBTAIN DENSE MASONRY:

In order to obtain dense masonry, following precautions shall be taken,
i) Under-pinning shall be avoided after a stone laid as it tends to lift the stone
and create air pockets.
ii) Putting chips in the intervening space before filling with mortar shall be
avoided.
iii) Leveling of masonry on the top of the course by use of chips, shall be
avoided. All chips on ends will be driven on one end only, which will help to
squeeze and compact the mortar in the joints.
3.2.5.7 LIMIT ON HEIGHT OF MASONRY TO BE DONE IN A DAY:

• The maximum height of masonry layer that will be allowed to be constructed
at a time shall be 0.6 meter.
• No fresh masonry shall be laid over masonry previously laid within 24 hours
of its laying.
3.2.5.8 WORK IN LINE AND PLUMB:

• The work shall be built square, plumb, curved or battered as may be required
by the design and drawings.
110
• It shall be carried out in a workman like manner with the aid of moulds, templates,
centres etc. which will be provided by the Contractor at no extra cost.
3.2.5.9 QUANTITY OF MORTAR:

• Every effort shall be made to see that proper quantity of mortar is used in the
masonry.
3.2.5.10 SCAFFOLDING TO BE DONE BY CONTRACTOR:

All scaffolding required for the work shall be provided within the rates quoted
for the items of masonry.
3.2.5.11 PROVIDING PLANKWAYS:

Plank walk ways or other suitable arrangement shall be provided at the
Contractor's cost promptly for the use of necessary job traffic over freshly laid
masonry of the day.
3.2.5.12 CURING OF MASONRY:

• All masonry as it progresses shall be kept well watered on the top and sides
for a period of not less than 14 days from the date of build -up place.
• The top of all masonry is to be kept well watered, watering shall be done
carefully so as not to disturb or wash out mortar.
• Where watering is done by manual labour, night shift, if necessary, shall be
arranged for constant watering.
• Masonry shall on no account be allowed to present a dry surface during curing
period.
• Should the mortar perish i.e., become dry through neglect of watering, such
work shall be demolished and rebuilt at no extra cost.
• If the curing arrangement of the Contractor is not satisfa ctory the Engineer-
in-charge may in his discretion engage labour and provide material,
equipment for curing and recover expenditure thus involved from the
Contractor.
3.2.5.13 WEAK OR DEFECTIVE MASONRY:

• If any portion of masonry is found to be defective either in materials or in
construction it shall be removed and rebuilt by the Contractor without extra
cost.
3.2.5.14 CLEANING AFTER CONSTRUCTION:

All masonry shall be cleaned after completion.
3.2.5.15 BLOCKOUTS AND SLOTS TO BE PROVIDED BY THE CONTRACTOR

• Block-outs and slots necessary for embedding the foundation bolts and other
embedded parts shall be provided by the Contractor without any extra cost.
3.2.5.16 DAMAGE DUE TO FLOODS, GOVERNMENT NOT RESPONSIBLE:

Any damages done to masonry due to the floods, passing over the work
completed in the previous working season, or caused due to floods during
111
construction, shall be covered by the rates quoted for the items. No extra claim
shall be entertained for such damages
3.2.6 MODE OF MEASUREMENTS AND PAYMENTS:

• Item shall be measured and paid on cubic meter basis.
• Payment shall be made on the net quantity of masonry arrived at, after deducting
quantities for openings and other class of work from the total volume of
masonry.
• Such deductions shall not apply to the anchor bars, grout holes, bore holes or
weep holes or any other opening not exceeding 100 sq. cm. in cross section.
• The Contractor shall submit the report covering all tests on material,
workmanship, finally laid masonry at required frequencies (The tests prior to
construction (Tests on materials-Stone, Cement, Sand), the tests at the time of
construction (Flow Test of mortar) and tests after construction (90cm Core of
Masonry).
• It should also cover the analysis of the tests and the conclusion for the
acceptance.
• Measurement shall be recorded after satisfactory report. The Engineer-in-Charge
will be responsible to verify and accept the report before accepting the
measurements.
• The quantity measured shall be paid only after removal of shuttering and curing the
masonry for specified period etc all complete.
Percentage of
Sr. No. Item
Payment
Measurements of work done for the final Bill

2 100%
Or measurement of portion for Final
112
3.3.0 DESCRIPTION OF ITEM: Providing, laying, erecting and
dismantling M.S. plates form work for side lining (for steeper slopes only)
(Item No. CC 9)
3.3.1 SCOPE OF WORK

The work covered by this item shall consist of furnishing all equipment, material and
labor for providing and erecting and dismantling M.S plate formwork for side lining
where the side slopes of canal are steeper.
3.3.2 MATERIAL
M.S plates of required thickness and M.S angles of standard specifications shall be used
for formwork.
Side channels, struts and nut and bolts of standard specification shall be used to support
the M.S plate formwork. The form work shall be used for maximum of 50 uses.

The subgrade shallbe prepared by removing all loose material, grass, bushes before
erecting the formwork. The formwork of M S plate shall be erected in proper alignment
and required slope. Before placing concrete, the surface of forms shall be oiled with
suitable nonstaining oil such as raw linseed oil such as to prevent sticking of concrete and
facilitate the removal of form. Immediately before concrete is placed, care shall be taken
to see that all forms are in proper alignment and the supports and fixtures are thoroughly
secured and tightened. Forms shall be left in place until their removal is authorized and
removal shall never be started until the concrete is thoroughly set and hardened
adequately to carry its own weight and any other load placed on concrete. The formwork
shall be removed without damaging the concrete.
3.3.4 MODE OF MEASUREMENT AND PAYMNT

The payment shall be made on area basis. The unit for payment shall be one square
metre.
113
Providing and laying polythene film of 031 properly manufactured from
100% virgin granules confirming to I.S. 2508-1984 with 1.5 to 2.5 m. package
in rolls/ as per specifications. (Item No. CC 10)
A) 200 microns
B) 400 microns
C) 600 microns
3.4.1 SCOPE OF WORK

A plastic membrane of polythene film 31 (200/400/600 micron) as mentioned in the item
is to be used below concrete lining in sides and bed where the sub-grade of the lining is
of pervious materials like murum etc., so as to prevent absorption of water in sub-grade
from green concrete during placement on the sub grade.
3.4.2 MATERIAL
The properties of the polythene film 31 are given as per IS code 2508-1984 as a guide
line, standards and as directed by Engineer in charge.
The contractor will be required to obtain necessary test certificate from the Government
Institute on samples of film to be used on work.

PLACING OF FILM:
The film thus approved is to be laid on the neatly, well dressed sub grade and fixed in
the subgrade so as to prevent displacement during the placement of concrete.
3.4.4 MODE OF MEASUREMENT AND PAYMENT:

Payment of work done under items of lining and laying polythene film will be made at
80% of the contract rate n R.A bill 100% of payment at the rate per sqm in final bill
may be released only after arresting leakage of water up to 90%.
114
3.5 PROVIDING AND LAYING CEMENT PLASTER 6 MM THICK IN
C.M. 1:3 (Item No. CC 12)

Providing and laying cement plaster 6 mm thick in C.M. 1:3 single coat without neru
finish to concrete surface in all position including scaffolding, curing, including etc.
complete. (Cement 0.057 bags/Sqm)
3.5.2 SCOPE OF WORK.

1. Erecting dismantling and removing the scaffolding.
2. Preparing the surface to receive the plaster.
3. Providing cement plaster of the specified average thickness.
4. All labours materials, use of tools and equipment’s to complete the plastering.
5.Curing for 14 days.
3.5.3 MATERIAL
a) SAND:
1.SOURCE AND SIZE:

The sand used for mortar shall be natural river sand or manufactured sand. The
2.QUALITY:
The sand shall consist of hard, dense, durable uncoated gritty material, obtained from
rock fragments. It shall be free from injurious amounts of dust, lumps, soft and flaky
particles, shale, alkali, organic matter, loam mica and other deleterious substances. The
maximum percentage of deleterious matter of sand as delivered for use in mortar shall
not exceed the following values.
Deleterious Matter PERCENTAGE BY WEIGHT

1 Materials passing 75-micron I.S. Sieve 3 Percent
2 Shale 1 Percent
3 Coal 1 Percent
4 Clay lumps 1 Percent
5 Total of other deleterious substances such as
Alkali, mica, coated grains, soft and flaky 2 Percent
particles
• The sum of percentage of all deleterious substances shall not exceed 5% by weight.
The sand shall be free from injurious amounts of organic impurities.
• Sand producing a colour darker than the standard in the colorimetric tests for organic
impurities shall be rejected.
• If the impurities are beyond the acceptable limits stated above, the sand shall be
washed with power/diesel driven sand washing machine to the entire satisfaction of
115
the Engineer-in-charge at the cost of the Contractor.
3. MECHANICAL ANALYSIS:
The natural sand shall be well graded and the sieve analysis of the sand shall confirm to
the following limits of gradation.
ASTM sieve No. Equivalent I.S.S. No. Cumulative percentage by

weight retained on Sieve
3/8" mesh 10.00 mm. Nil
4 mesh 04.75 mm. 1 to 8
8 mesh 02.36 mm. 10 to 25
16 mesh 01.18 mm. 25 to 45
The gradation curve of the natural sand shall lie within the enveloping curve of
gradation specified as above.
4. FINENESS MODULUS:
• The fineness modulus shall be computed by adding cumulative percentages of sand
retained on the 6 standard sieves from No. 4 to No. 100 both inclusive A.S.T.M.
standard (or 4.75 mm., 2.36 mm., 1.18 mm. 600 microns, 300 microns, and 150
microns of the ISI specification) and dividing the sum by 100.
• Any deviation from the specified range of gradation and fineness modulus shall not be
permitted without the written permission of the Engineer-in-charge.
• Corrective measures if any required for improving the fineness modulus shall be
arranged by the Contractor at his own cost as directed by the Engineer-in-charge.
5. NATURAL SAND:
Natural sand shall have a fineness modulus ranging from 2.60 to 3.85 without any
admixtures.
6. ALLOWANCE FOR BULKAGE:

• If the sand as obtained from quarry or after its washing is found to be moist, bulkage
will be measured and allowance provided.
• Sand is stacked at site at least for 48 hours before use. Bulkage of such stack will be
measured regularly as directed by the Engineer-in-charge and allowed according to
these observations.
116
Below 5% NH
5 to 10 5 percent
10 to 15 10 Percent
15 to 20 15 Percent
20 to 25 20 Percent
25 to 30 25 Percent
30 to 35 30 Percent
b) CEMENT:
Cement used shall be any of the following and the type selected as per the contract
conditions, specifications and drawings.
The cement will be procured in standard bags as received from the manufacturers and is
expected to conform with the specifications, laid down by Bureau of Indian Standards.
The volume of one undamaged bag shall be considered as 0.034 cubic meter.
c)WATER:
1.QUALITY:
Water used for making mortar shall be reasonably clean and free from objectionable
quantities of silt, organic matter, alkali, salts and other injurious materials.
2. TURBIDITY PERMISSIBLE:
The turbidity of water for mixing mortar not be more than 2,000 parts per million and
shall preferably be as low as possible.
3.5.4 PROPORTION:
• Cement and sand shall be mixed in 1:3 or 1:4 as directed.
• The mortar shall be machine mixed.
• The specifications for sand, cement and water given under Para 6.4, 6.5 & 6.6 shall be
applicable. (Page No. M-2 to M-5)
• Mixing platform shall be so arranged that no deleterious extraneous materials shall get
mixed with mortar not the mixing water of the mortar shall flow out.
• The mortar prepared shall be used within 30 minutes of adding water.
3.5.5 SCAFFOLDING:
• Scaffolding required for facility of construction shall be provided by the Contractor at
his expense.
• Scaffolding will be double or, single as is warranted for the particular class of
117
masonry.
• But the ends of poles should not be placed in the position of header stones.
• Scaffolding shall be erected by bellies or bamboos of adequate strength so as to be
safe for all.
3.5.6 CONSTRUCTION OPERATIONS.

• The Contractor shall take all measures to ensure the safety of the work and working
people.
• The Contractor shall be entirely responsible for any damage to property or injury to
persons resulting from ill erected scaffolding, defective ladders and materials or
otherwise arising out of his default in this respect.
• Proper scaffolding shall be provided to allow easy approach for every part of the work.
• Overhead work shall not be allowed.
• Long holes in masonry shall be made good by concrete M-20 to match the face work,
when scaffolding is being removed after ensuring that all holes behind are solidly filled
in with concrete M-20.
3.5.7 GAUGES:
• Patches of plaster 15 cm. x 15 cm. shall be put about 3 meters apart as gauges to,
ensure even plastering in one plane.
3.5.8 PLASTERING:
• In all plaster work the mortar shall be firmly applied with somewhat more than the
required thickness and well pressed into the joints and on the surface and levelled with
a flat wooden rule to give required thickness.
• Long straight edges shall be freely used to ensure a perfect plane and even surface.
• All corners must be finished to their true angles or rounded.
• The surface shall be finished to plane or curved surface as shown on drawing and shall
present a neat appearance.
• Cement plastering shall be done in square or strips as directed.
• Plastering shall be done from top to downward.
3.5.9 FINISHING AND CURING:

• Wall finishing treatment of any type should be carried out continuously for a period
of 14 days to prevent excessive evaporation on the sunny or windward side in hot dry
weather.
• Matting or gunny bags may be hung over on the outside of the plaster in the beginning
and kept moist.
• Should the contractor fail to water the work to the satisfaction of Engineer-in-charge
the latter may engage requisite labour, materials and equipment to the work properly
at the cost of the contractor.
• 3.5.10 MODE OF MEASUREMENT AND PAYMENT:
• Plastering of specified thickness shall be measured on square meter basis.
• Dimensions shall be measured up to two places of decimal.
118
3.6 EXPANSION / CONSTRUCTION JOINT with 18 SWG copper plate
and shalitex expansion pad (Item No. CC 19)

Providing and laying expansion / construction joint with 18 SWG copper plate and
shalitex expansion pad below and above the copper plate including sealing the joint with
shalitex compound etc. complete including 50 x 50x 5 mm. angle frame with stainless
steel bolts etc. (For all slab thickness)
3.6.2SCOPE OF WORK:
The work covered under this item shall consist of furnishing all equipment, material and
labour for providing welding and brazing, transporting, placing of copper joints applying
plastic compound and performing all the function necessary and ancillary thereto
including finishing to the required shape and size as directed by the Engineer-in charge.
The joints shall be located in the structure as directed. The Contractor shall cut,
shape and braze plates and place them in the construction joint as shown in drawing.
The plates shall be of specified thickness. Adequate provision shall be made to support
& protect the metal strips which are damaged before final acceptance of the work.
3.6.3 MATERIAL:
Copper plates shall be of malleable copper which can be formed in to the required shape
without cracking.
The M.S angle/ M.S plate and stainless-steel bolts shall be as per specifications.
3.6.4 SEQUENCE OF EXECUTION:

1. The details of the joint are shown in the drawing.
2. At the place of joint, a pitch of size 70 mm. x 35 mm. on each side with a gap of
25mm. in between shall be kept in the concreted portion of boxes. The 70 mm. long
pith is already providing with stainless steel bolt of 6 mm. dia. 300 mm.c/c, clamping
M, S plate 6 mm. thick, a gasket 6 mm think which are in position as shown on the
drawing. The annular space between steel bolts and adjacent portion i.e., concrete shall
be filled with rubber solution at the time of installations.
3. In the finalized pitch, the top portion of stainless-steel bolts shall be protruding to the
required length.
4. At the time of fixing the copper plate in position, the necessary loop shall be provided.
The loop of copper plate shall remain clear in the gap in between. For this purpose,
templates shall be used so that the loop does not get embedded in the concrete. The
loop shall be on the canal side.
5. The top clamping plate shall be positioned over the copper plate and nuts shall be
sufficiently tightened so that there is no gap between copper plate and clamping plate
and leakage of water avoided.
6. Joint sealing compound shall be provided at the ends as shown n drawing. Nuts shall
be provided with plastic cap.
119
7. The space of pitch shall be provided with C.M 1:2. However, proper care shall be
taken to see that the gap in between remains clear of the mortar.
8. The bituminous filler on water side shall be provided as shown on drawing.
9. The M.S plate below and above copper plate shall be fabricated in suitable lengths,
10. In order to prevent rusting, the M.S plate shall be coated with paint before
installation.
11. The Engineer-in-charge shall be competent to order more instructions or revise
or modify some of them to ensure water tightness of the joint.

The unit of measurement shall be per metre length of joint.

The interim payment payment shall be made at 80% of the rate quoted for the item till
testing of aqueduct is completed and joints are found to be watertight to the extent required as
desired by the Engineer-in-charge.
120
3.7 EXPANSION / CONSTRUCTION JOINT with Shalitex super expansion
pad (jute fiber) (Item No. CC 20)

Providing and laying expansion / construction joint with shalitex super expansion pad
(jute fibre) 12mm thick including sealing the joint with shalitex sealing compound etc.
complete. (For all slab thickness)

The item includes all material labour, equipment required for providing and laying
expansion / construction joint with Shalitex expansion pad of required thickness
including sealing the joint with shalitex sealing compound
3.7.3 MATERIAL
Shalitex super expansion pad shall conform to I.S: 1838. The thickness shall be as
mentioned in the item and drawing.

1. The joints shall be located in the structure as directed. The contractor shall cut, shape
and place them in expansion /construction joints as shown in drawings. The pad shall
be of specified thickness.
2. The joint shall be properly sealed with Shalitex sealing compound.
3.7.5 MODE OF MEASUSUREMENT:

The length and depth of slab shall be measured and the area of joint calculated.

The unit of payment shall be one Square Metre.
121
3.8 PROVIDING AND FIXING G.I. SHEET (Item No. CC 21)

Providing and fixing G.I. sheet 24 gauge and 22.5 cm. wide for the construction joint in
R.C.C. trough wall including cutting 15 cm. overlap, riveting the joints and fixing in
position etc. complete.

This Specifications covers the requirements for Providing and fixing G.I. sheet 24 gauge
and 22.5 cm. wide for the construction joint in R.C.C. trough wall including cutting 15
cm. overlap, riveting the joints and fixing in position.
3.8.3 MATERIAL
Plain and corrugated galvanized iron sheeting shall conform to requirements of Indian
Standard: 277 – Class 2, that is, having a heavy coating of zinc weighing on an average
2 oz. per sq. ft. (610 gms. per sq. cm.). The gauge shall be as specified. If not otherwise
specified, the sheets shall be of 22 Birmingham gauge (0.80 mm thick). The 22
Birmingham gauge (0.80 mm thick) galvanized iron sheet (Class 2) weights 1.368 lb/sft.
(6.676 kg. per sq. metre). The sheets shall be clean, bright, from rust, uninjured in carriage
by the rubbing of zinc covering, and show no signs of white powdery deposit on the
surface.

The work covered by this item shall consist of furnishing all equipment material and
labour for providing, riveting, transposing, placing of G. I. sheet joints, and performing
all the functions necessary and ancillary thereto including finishing to required shape and
size as directed by the Engineer-in-charge.
3.8.5 Mode of Measurement

The rate shall be per metre of joints. The completed rate shall include all materials, G. I.
sheet, M.S. rods, bituminous filler, cement, rivets etc. and all labour etc. complete.
3.8.6 Mode of Payment

100% payment shall be made after satisfactory completion of work, certified by engineer-
in-charge.
122
3.9 STEEL REINFORCEMENT (Item No. CC 22)
3.9.1 Description of Item
Providing, fixing & erecting including cutting, bending, hooking, laying in position and
tying M.S./HYSD/TMT bars for reinforcement of R.C.C. work as per detailed drawing
etc. complete.

This Specification covers the requirements for Cutting, bending, hooking, laying in
position and tying M.S./HYSD/TMT bars for reinforcement of R.C.C. work as per
detailed drawing etc. complete.
3.9.3 MATERIAL SPECIFICATIONS

The contractor shall make his own arrangement for procurement of steel reinforcement
i.e. bars and binding wires for use in reinforced cement concrete works. Unless otherwise
specified in drawing / Schedule of quantities, the steel bars shall be “High strength
deformed” steel bars and conforming to the IS 1786 (latest revision and amendments), in
the following strength grades:
Fe 500, Fe 500D;
Fe 550, Fe 550D; and
Fe 600.
Where “Fe” stands for steel, followed by number specifying minimum 0.2% proof /
yield stress in N/mm² and “D” stands for enhanced ductility specified by percentage
elongation.
TESTS-
The reinforcement material shall be tested for its
i) chemical,
ii) Physical &
iii) Mechanical properties
as per relevant IS codes. (e.g., Carbon contents, Elongation, Proof Stress, tensile
strength, bend & re-bend test)
The contractor shall submit the test certificate of manufacturer.
Regular confirmation tests on steel supplied by the contractor shall be performed by the
Engineer-in-charge in the Quality Control laboratories in presence of the Contractor or
his authorised representative.
The contractor shall make the samples available for the tests with no cost.
Engineer-in-charge may require Contractor to perform necessary tests as per relevant
IS, on samples drawn at random representing the lot supplied. The quality, grade, colour
coding, embossing marks etc. all shall be to the entire satisfaction of the Engineer-in-
Charge.
Steel not conforming to test criteria shall be rejected. Unless otherwise specified,
selection and preparation of test sample shall be as per the requirements of IS 2062.
123
Normally for chemical analysis, manufacturer’s certificate is acceptable, unless there is
prima-facia case to doubt against the same.
In all cases physical & mechanical properties of the steel reinforcement bars shall be
tested.
All test pieces shall be selected either from the cuttings of bars / wires; or from any
bar/wire after it has been cut to the required or specified size and the test piece taken
from any part of it.
In neither case, the test piece shall be detached from the bar/wire except in the presence
of the Engineer- in- charge or his authorized representative.
The test pieces shall be full sections of the bars/wires and shall be subjected to physical
tests without any further modifications.
No reduction in size by machining or otherwise shall be permissible, except in case of
bars of size 28 mm and above.
No test piece shall be annealed or otherwise subjected to heat treatment. Any
straightening which a test piece may require shall be done cold.
For the purpose of carrying out tests for tensile strength, proof stress, percentage
elongation and percentage elongation at maximum force for bars 28 mm in diameter
and above, deformations of the bars only may be machined.
For such bars, the physical properties shall be calculated using the actual area obtained
after machining.
The following IS codes shall be referred for test methods:
Sr. No. Title I.S. No.
1 Mechanical testing of metals -Tensile testing 1608
2 Methods for bend test 1599, 7438 & 1786
3 Method for re-bend test for metallic wires & bars 1786
Chemical Composition of the bars shall conform to the requirement as per IS 1786:
Notes: For mechanical tests-
1. For welding of deformed bars, the recommendations of IS 9417 shall be followed.
2. In case of deviations from the specified maximum, two additional test samples shall
be taken from the same batch and subjected to the test or tests in which the original
sample failed. Should both additional test samples pass the test, the batch from which
they were taken shall be deemed to comply with this standard. Should either of them
fail, the batch shall be deemed not to comply with this standard.
124
Maximum Permissible Percentage
Constituents
Fe 500 Fe 500D Fe 550 Fe 550D Fe 600
Carbon 0.3 0.250 0.30 0.25 0.30
Sulphur 0.055 0.040 0.055 0.040 0.040
Phosphorous 0.055 0.040 0.050 0.040 0.040
Sulphur & Phosphorous 0.105 0.075 0.100 0.075 0.075
Mechanical properties of High strength Deformed Bars & Wires
Fe
Sr Fe Fe Fe Fe Fe55 Fe550 Fe60
Property 500
No 415D 415S 500 500D 0 D 0
S
1 2 3 4 5 6 7 8 9 10
0.2% proof Stress/

i 415 415 500 500 500 550 550 600
Yield Min N/mm2
0.2% proof Stress/

ii - 540 - -- 625 - - -
Yield Max N/mm2
≥ ≥ ≥ ≥
≥ 1.12
1.08 1.10 1.06 ≥ 1.08 1.06
(But
(But (But (But (But (But
TS/YS ratio, TS≥
iii 1.25 TS≥ TS≥ 1.25 TS≥ TS≥ TS≥
N/mm2 500
545 565 585 600 660
N/mm
N/m N/m N/m N/mm2 N/m
2
m2 m2 m2 m2
Elongation, %,
Min on gauge
Length 5.65√A
iv 18.0 20.0 12.0 16.0 18.0 10.0 14.5 10.0
Where A is cross-
sect. area of the
Test piece (3.9)
Total Elongation at
Max Force, % Min.
on gauge Length
v 5.65√A Where A is 5 10 - 5 8 - 5 -
cross-sect. area of
the Test piece
see foot note 2)
125
1) TS/YS ratio refers to ratio of tensile strength to the 0.2% proof stress or Yield stress
of the test piece.
2) Test, wherever specified by the purchaser.
Note: To satisfy Clause 26 of IS 456 (Latest version & amendments) no mixing of different
grades of bars shall be allowed in the same structural members as main reinforcement,
without prior written approval of the Engineer-in-Charge.
Standard weight, cross sectional area of bars
Nominal size in mm 6 7 8 10 12 16 18 20
Cross Sectional area 28.30 38.50 50.30 78.60 113.10 201.20 254.60 314.30
in
Mass/Weight in 0.222 0.302 0.395 0.617 0.888 1.580 2.000 2.47

Kg/RM
Nominal size 22 25 28 32 36 40 45 50
in mm
Cross
Sectional area 380.30 491.10 614.00 804.60 1018.30 1257.20 1591.10 1964.30
in
Mass/Weight 2.980 3.850 4.830 6.310 7.990 9.850 12.500 15.420

in Kg/RM
No allowance shall be made/ measured in the weight for rolling margin. If weight of
bar(s) found to be more than the standard weights, the measurement / payment shall be
restricted to the standard weights as above.
However, if weight of bar(s) found to be less than the standard weights (but within the
permissible limit), the measurements/ payment for the same shall be as per standard
weights.
The cost of steel used by the contractor in the reinforcement of component of any
structure, will be paid as per the rate of reinforcement only up to the extent shown in the
drawings.
Use of small length bars shall be avoided.
The rate shall include the cost of all materials and labour required for all above operations
including transport, wastage, straightening, cutting, bending, binding and the binding
wire required.
126
Storage -
Steel for reinforcement shall be stored in such a way as to prevent distorting and
corrosion. The steel for reinforcement shall not be kept in direct contact with ground.
Fresh / Fabricated reinforcement shall be carefully stored to prevent damage, distortion,
corrosion and deteriorations. Care shall be taken to protect steel from exposure to saline
atmosphere during storage, fabrication and use. Refer IS 4082 for storage. It may be
achieved by treating the surface of reinforcement with cement wash or by suitable
methods. Bars of different classifications, sizes and lengths shall be stored separately to
facilitate issue in such sizes and lengths to cause minimum wastage in cutting from
available lengths.
Quality:
Steel not conforming to specifications shall be rejected. All reinforcement shall be clean,
free from grease, oil, paint, dirt, loose mill scale, loose rust, dust, bituminous material or
any other substances that will destroy or reduce the bond. All rods shall be thoroughly
cleaned before being fabricated. Pitted and defective rods shall not be used.
All bars shall be rigidly held in position before concreting. No welding of rods shall be
allowed unless approved by the Engineer-in-Charge. If welding is approved, the work
shall be carried as per IS 2751, according to best modern practices by trained and certified
welders, and as directed by the Engineer-in-Charge. In all cases of important connections,
tests shall be made to prove that the bar breaks outside the butt or lap welded joints. Refer
IS 9417 for welding of cold worked bars. Weld shall be in straight portion of the bars and
not along the curved portion of bent bar. Substitution of reinforcement by other grade
will not be permitted except upon written approval from Engineer-in-charge.
Nominal Sizes
The nominal sizes of bars/wires shall be 6 mm, 8 mm, 10 mm, 12 mm, 16 mm, 20 mm,
25 mm, 28 mm, 32 mm, 36 mm, 40 mm. (Other sizes viz. 7mm, 18mm, 22 mm, 45 mm
and 50 mm may be procured on specific stipulations).
Nominal Mass
For the purpose of checking the nominal mass, the density of steel shall be taken as
0.00785 g/mm3 of the cross-sectional area per meter. Unless otherwise specified, the
tolerances on nominal mass shall be as per following Table.
Nominal Size in mm Tolerance on the Nominal Mass per cent
Individual Sample Individual Sample for coil

Batch
+ (x)
(a) Up to& including 10 +/- 7 -8 +/- 8
127
(b) Over 10, up to & including
+/- 5 -6 +/- 6
16
(c) Over 16 +/- 3 -4 +/- 4
Note:- For Individual samples plus tolerance not specified.
Laps-
Laps and splices for reinforcement shall be shown on approved drawings or approved bar
bending schedule. As far as possible splices in adjacent bars shall be staggered and the
locations of all splices, except those specified on the drawings, shall be approved by the
Engineer-in-Charge. Where splices are not staggered, the lap length shall be suitably
enhanced. As far as possible, splices shall be minimized in the reinforcement, depending
upon the lengths of bars available at site.
Bar Bending Schedule
The contractor shall prepare bar bending schedules for all the reinforcement work and get
it approved from Engineer-in-Charge.
For important members the scheme of tying bars and fabrication of reinforcement cage
shall be planned and got approved.
Bars shall be accurately bent according to the sizes and shapes shown on the detailed
working drawings and as per bar bending schedule.
Bars above 32 mm dia. shall be bent gradually by machine or other approved means. Bars
containing cracks or splits shall be rejected. IS 2502 and IS 5525 shall be referred for
bending and fixing of bars.
The reinforcement cage or mat as finally tied, fabricated and fixed in position should be
stiff enough such that bars will not move due to workers movement and construction
operations while concrete is being poured or is setting. Movements over fresh concrete
shall be avoided.
Bending at Construction Joints:
Where reinforcement bars are bent aside at construction joints and afterwards bent back
into their original position, care should be taken to ensure that at no time the radius of the
bend is less than 4 bar diameters for plain mild steel or 6 bar diameters for deformed bars.
Care shall also be taken when bending back bars to ensure that the concrete around the
bar is not damaged.
Fixing / Placing and Tolerance on Placing
Reinforcement shall be accurately fixed by any approved means maintained in the correct
position as shown in the drawings using blocks, spacers and chairs as per IS 2502 to
128
prevent displacement during placing and compaction of concrete. Bars intended to be in
contact at crossing point shall be securely tied together at all such points with number 16
gauge annealed soft iron wire.
Tolerance in Placing of Reinforcement:
Unless otherwise specified, reinforcement shall be placed within the following

tolerances:
a) For effective depth, 200 mm or less + /- 10 mm
b) For effective depth, more than 200 mm + /- 15 mm
Cover to Reinforcement:
To meet durability requirement minimum values for the nominal cover should be
provided to all reinforcement, including links depending on the condition of exposure;
and shall be as per provisions of IS 456 (Table 16 and 16A).
Precast cover blocks of micro concrete or readymade spacers available in the market shall
be used. It should have sufficiently high strength to avoid its fracture during assembly of
reinforcement and pouring of concrete and should be able to bear the live loads
transferred through the bars.
Maintaining Positions of Bars:
a) Chairs: In case of thick slabs, cantilevered and doubly reinforced beams the vertical
distance between the top and bottom bars or position of top layer bars shall be
maintained by introducing chairs, spacers or support bars of steel at 1.0 meter or at
shorter spacing to keep the effective depth as per drawing.
b) All vertical bars shall be kept in plumb by providing rigid supports.
c) In case of structures such as arches, domes, shells, curve shaped water tanks etc.
reinforcement shall be kept in position as per the drawings.
The rate of the reinforcement includes all these provisions.
Inspection:
The final placed reinforcement shall be inspected and approved by Engineer-in-Charge

prior to placement of concrete. The Engineer-in-charge shall make arrangements for cross
verification of placed reinforcement either from the design engineer or the third-party
engineer.
129
List of India Standard Codes
1 1786 Re-bend tests for Wires and Bars
2 1608 Mechanical testing of steel

3 2502 Bending & Fixing of Bars
4 5525 Detailing of Reinforcement
5 9417 Welding Cold Worked Bars
6 4082 Stacking & Storage of construction materials & components at site
7 2751 Welding of Bars for RCC works.

• Reinforcing steel shall be thoroughly cleaned of all coatings of any characters that
would destroy or reduce the bond.
• Bending reinforcement shall conform accurately to the dimensions and shapes shown
on the plans or as directed by the Engineer.
• Bars shall not be bent or straightened in a manner that will injure the material. Bars
with kinks, bends or cracks shall not be used.
• Bars shall be bent cold to the shapes and dimensions shown on the drawings or as
directed by the Engineer in writing. Bar bender may be used to attain proper radii of
bends and shapes.
• Bars which may be bend in transport or handling shall be properly straightened before
being placed in work without heating them.
• Bending bar by heating to cherry red heat not exceeding 815øc may be allowed for
only M.S. bars larger than 25mm. diameter except for bars which depend for their
strength on cold working. Hot bars shall not be cooled by quenching.
• HYSD bars shall not be heated for bending.
• Details of length, sizes, laps and bending diagrams shall be got approved by
the Engineer. This is to secure additional precautions against errors.
• Steel reinforcement bars and fabrics shall be placed in the concrete as shown in the
Drawing or as directed.
• Before steel reinforcement is placed in position the surface of the reinforcement shall
be cleaned of rust, scale, dirt and grease and other
objectionable foreign substances (heavy flaky rust and Mill scale that cannot be removed
by firm rubbing with burlap, or equivalent treatment is considered objectionable). The
fact that light or early-stage rust has no detrimental effect on bond and hence could be
discharged shall not be used as excuse of careless handling and storage of steel. In
storing bars of the same size, length shapes and grade shall be assembled in racks and
marked distinctly.
130
• Before the reinforcement bars are fixed in position it shall be verified that they are of
specific size and bent in accordance with the plans and specifications. They shall be
accurately placed and secured in position by means of built-in concrete block, metallic
chairs, hangers, spacers and othersuitable devices, at sufficiently close Intervals, so
that they will not sag between supports, not be displacing of the concrete or by any
operation of the work.
• Special care shall be exercised to prevent any disturbance of the reinforcement in
concrete that has already been placed. The reinforcement after being placed in position
shall be maintained in a clean condition until it is completely embedded in concrete to
prevent further damage to the concrete or unsightly rust stains on exposed concrete
surface.
• Reinforcement shall not be straightened or bend in a manner that will injure or weaken
the materials. Bars with kinks or bends not shown on the plans shall not be used. Bars
shall be bent to the shape and dimensions shown on the drawing or as directed, using
a bar bender, operated by hand or power, to attain the proper bending radius.
• The radius of bend shall not less than 4 times the nominal size of the bar. Heating of
reinforcement bars to facilitate bending will not normally be permitted when,
however, such heating is permitted in the case of large diameter bars, the temperature
of the steel shall not exceed the corresponding to a cherry red color.
• The distance between two parallel reinforcement bars shall be except as provided
below in 14.4.2 not less than the greatest of the following distances.
a) The diameter of either bar, if their diameters be equal,
b) The diameter of the larger bar, if their diameters be unequal.
c) 6 mm. more than the nominal maximum size of the coarse aggregate comprised in
such concrete.
• The vertical distance between two horizontal main steel reinforcements or the
corresponding distance at right angles to two inclined main steel reinforcements shall
be not less than 12 mm. except at a splice or lap and except where one of such
reinforcement is transverse to the other.
• The pitch of the main bars in a reinforced concrete solid slab shall be not more than
three times the effective depth of such slab, or 60 cm whichever is less Bar splices as
indicated in the drawing or as specified by the Engineer-in-charge shall only be
allowed. The lapped ends shall be placed to ensure full bond on each bar.
• Splicing shall not be done in the region of maximum bending moment, and splicing
of adjacent bars shall be avoided as far as possible.
• Welding of bars for splicing may be allowed in place of lapping at the discretion of
the Engineer-in-charge at approved locations. When welding is resorted, instead of
lapping, the bar to be spliced shall be lap welded or butt welded by electric arc
welding.
• Ends of bars to be spliced shall be cleaned of all dirt, scales, rust paint andForeign
matter before welding. All welding shall confirm to the relevant Indian Standard
Specification. Any weld will be considered un-satisfactory if it fails to sustain a tensile
stress of at least 90% of the tensile stress of the bar in which the weld has been made.
131
• The Contractor shall make necessary arrangements, for carrying out the tests as
directed by the Engineer-in-charge and with the accepted unit rate for reinforcement.
Sufficient concrete cover shall be provided to protect reinforcement from corrosion or
as indicated in the drawings. All protruding bars from concrete or masonry to which
other bars are to be spliced and which will be exposed to action of weather for an
indefinite period shall be protected from rusting by a thin coat of neat cement grout.
• The thickness of concrete cover (exclusive of plaster or other decorative finish) shall
be as follow.
a) At each end of reinforcing bar, a cover not less than 25 mm. nor less than twice the
diameter of such rod or bar.
b) For a longitudinal reinforcing bar in a column cover not less than 40 mm. nor less
than the diameter of such rod or bar in the case of column of minimum dimensions
of 18 mm. or under those bars which do not exceed 12 mm. diameter, 25 mm. cover
may be used.
c) For a longitudinal reinforcing bar in a beam a cover not less than 25 mm nor less
than the diameter of such rod or bar
d) For tensile, compress/e shear or other reinforcement in a slab a cover, not less than
12 mm. nor less than the diameter of such reinforcement.
e) For all external work for work against earth faces and. also for internal work where
there exist particularly corrosive conditions, the cover, of the concrete shall be
increased by 12 mm. beyond the figures given above (a to d). Where because of
splicing, the thickness of concrete in between reduces to less than the maximum
size of the aggregate a concrete with reduced maximum size of aggregate shall be
used so as to allow development of bond in the splice.
• The extra cost of such special concrete shall be deemed to have been included in the
unit rate for the main concrete and shall i.e., paid at the same rate
• No concreting shall be started unless the reinforcement as laid is finally checked and
certified by the Engineer-in-charge or his authorized representative. Before starting
the concreting, the Contractor shall make certain that the measurements of the
reinforcement placed in have been recorded and that the Engineer-in-charge certifies
the correctness of enforcement used.
• Failure to do so may mean no payment or payment at the discretion of the Engineer-
in-charge for the reinforcement concrete.

The steel reinforcement shall be measured and paid on metric tonne basis.
Reinforcement as detailed in schedule of quantities shall be measured for payment
linearly as per the cutting length nearest to a centimeter shown in bar bending schedule
and weight calculated based on the standard weights as per I.S.1786 as indicated
below:
• The measurements will be taken only after, satisfactory test results are obtained as per
norms & frequencies specified in BIS codes & Quality Control Manuals.
132
• The bars binding is done as per approved drawings & as per approved bar bending
schedule.
• The steel reinforcement is checked by third party engineer for its correctness.
• All do's & don'ts are followed.
• Accurate records shall be kept at all times of numbers, size, length and weight of bars
placed in position for different parts of the work. The reinforcement shall be paid as
the weight of actual quantity of steel reinforcement placed in the structure arrived at
the time of measuring the actual length of the bars used and placed as shown in the bar
bending schedules including hooks, bends and laps. The length of the bar shall be
measured to the next nearest 10 cm. a fraction less than 5 cm. being neglected and
fraction of 5 cm. more taken as 10 cm. Weight shall be computed from the standard
table of weights.
• The unit rate accepted for the reinforcement shall include the cost of supplying,
cutting, bending, cleaning, straightening, fixing and maintaining in position the
reinforcement. Supplying and attaching binding wire, supports separators, hangers
etc., shall be deemed to be included in the unit rate for reinforcement and shall not be
measured nor paid where welding is permitted, for splicing, shall not be paid for
separately.
• Chairs if any provided as per instruction of Engineer-in-charge will be paid separately.

100% payment shall be made after satisfactory completion of work, certified by
engineer-in-charge.
Sr No Item Percentage of
Payment
Measured during R.A. Bill after all the QC tests conducted are
1 satisfactory
(Provided concreting is done for the portion) 90%
At the time of Final Measurements and after satisfactory

performance is tested
2
Or
At the time of Measurement for the final. 100%
133
3.10 PROVIDING, ERECTING AND LAYING STEEL SHUTTERING
FORMWORK
(Item No. CC 23)

Providing, erecting and laying steel shuttering formwork and making surface suitable
for concreting including dismantling etc. complete as directed.
(a) For abutments, piers, wings, returns etc. complete
(b) For RCC Solid/Deck slab/Box Cells/ Trough of Aqueduct etc.
(c) For curved surface
3.10.2 SCOPE OF WORK

This Specifications covers the requirements for providing, erecting and laying steel
shuttering formwork and making surface suitable for concreting including dismantling.
3.10.3MATERIAL SPECIFICATIONS
• The prop system consists of temporary structures made of steel, which is intended to hold
the shape of the concrete. The steel prop can be reused in many different kinds of works.
• All propping should be either of steel tubes (readymade props) with extension pieces or
built-up sections of rolled steel. It can also be of any engineered material as per
• The design of form work shall conform to sound Engineering practices and relevant IS
codes

• Props should be checked to ensure that, wrong items/ rejects are not used.
• If there are any excavations nearby which may influence the safety of form works,
• The bearing soil must be sound and well prepared and the sole plates shall bear well
on the ground.
• Sole plates shall be properly seated on their bearing pads or sleepers.
• The bearing plates of steel props shall not be distorted.
• The steel parts on the bearing members shall have adequate bearing areas.
• Safety measures to prevent impact of traffic, scour due to water etc. should be taken.
• Bracing, struts and ties shall be installed along with the progress of form work to
ensure strength and stability of form work at intermediate stage. Steel sections
(especially deep sections) shall be adequately restrained against tilting, overturning
and form work should be restrained against horizontal loads. All the securing devices
and bracing shall be tightened.
• The stacked materials shall be placed as catered for, in the design.
• When adjustable steel props are used, they should: be undamaged and not visibly
bent.
134
• have the steel pins provided by the manufacturers for use.
• be restrained laterally near each end.
• have means for centralizing beams placed in the forkheads.
• Screw adjustment of adjustable props shall not be over extended.
• Double wedges shall be provided for adjustment of the form to the required position
wherever any settlement/ elastic shorting of props occurs. Wedges should be used only
at the bottom end of single prop. Wedges should not be too steep and one of the pair
should be tightened/ clamped down after adjustment to prevent shifting.
• No member shall be eccentric upon vertical member.
• The number of nuts and bolts shall be adequate.
• All provisions of the design and/or drawings shall be complied with.
• Cantilever supports shall be adequate.
• Props shall be directly under one another in multistage constructions as far as possible.
• Guy ropes or stays shall be tensioned properly.
• There shall be adequate provision for the movements and operation of vibrators and
other
• construction plant and equipment.
• Required camber shall be provided over long spans.
• When formwork is dismantled, its individual components shall be examined for
damage and damaged pieces shall be removed for rectification. Such examination
shall always be carried out before being used again. Before re-use all components shall
be cleaned of deposits of soil, concrete or other unwanted materials. Threaded parts
shall be oiled after cleaning.
• All bent steel props shall be straightened before re-use. The maximum deviation from
straightness is 1/600 of the length. The maximum permissible axial loads in used props
shall be suitably reduced depending upon their condition. The condition of the steel
shuttering plates shall be examined closely for distortion and defects before re-use.
• In case the height of props exceeds 3.50 meter, the prop shall be provided in multi-
stages.

• Where it is stipulated that the form work shall be paid for separately, measurements
shall be taken of the area of shuttering in contact with the concrete surface.
• Dimensions of the form work shall be measured correct to a cm.
• Centering, and shuttering where exceeding 3.5 metre height in one floor shall be
measured and paid for separately.
• Where it is not specifically stated in the description of the item that form work shall
be paid for separately, the rate of the RCC item shall be deemed to include the cost of
form work.
• No deductions from the shuttering due to the openings/ obstructions shall be made if
the area of each openings/ obstruction does not exceed 0.4 square metre. Nothing extra
shall be paid for forming such openings.
135
• Form work of elements measured under categories of arches, arch ribs, domes, spiral
staircases, well steining, shell roofs, curvilinear folded plates & curvilinear eaves
board, circular shafts & chimneys shall not qualify for extra rate for circular work.

100% payment shall be made after satisfactory complete of work, certified by engineer-
in-charge.
136
3.11 PROVIDING AND ERECTING STEEL PROPS CENTERING
(Item No. 24)

Providing and erecting steel props centering up to 3.00 m height including bracing,
strengthening and dismantling etc. complete.

This Specifications covers the requirements for Providing and erecting steel props
centering up to 3.00 m height including bracing, strengthening and dismantling

• The prop system consists of temporary structures made of steel, which is intended to
hold the shape of the concrete. The steel prop can be reused in many different kinds
of works.
• All propping should be either of steel tubes (readymade props) with extension pieces
or built-up sections of rolled steel. It can also be of any engineered material as per
• The design of form work shall conform to sound Engineering practices and relevant
IS codes

• Props should be checked to ensure that, wrong items/ rejects are not used.
• If there are any excavations nearby which may influence the safety of form works,
• The bearing soil must be sound and well prepared and the sole plates shall bear well
on the
• ground.
• Sole plates shall be properly seated on their bearing pads or sleepers.
• The bearing plates of steel props shall not be distorted.
• The steel parts on the bearing members shall have adequate bearing areas.
• Safety measures to prevent impact of traffic, scour due to water etc. should be taken.
• Bracing, struts and ties shall be installed along with the progress of form work to
ensure strength and stability of form work at intermediate stage. Steel sections
(especially deep sections) shall be adequately restrained against tilting, over turning
and form work should be restrained against horizontal loads. All the securing devices
and bracing shall be tightened.
• The stacked materials shall be placed as catered for, in the design.
• When adjustable steel props are used. They should: be undamaged and not visibly
bent.
• have the steel pins provided by the manufacturers for use.
137
• be restrained laterally near each end.
• have means for centralizing beams placed in the forkheads.
• Screw adjustment of adjustable props shall not be over extended.
• Double wedges shall be provided for adjustment of the form to the required position
wherever any settlement/ elastic shorting of props occurs. Wedges should be used only
at the bottom end of single prop. Wedges should not be too steep and one of the pair
should be tightened/ clamped down after adjustment to prevent shifting.
• No member shall be eccentric upon vertical member.
• The number of nuts and bolts shall be adequate.
• All provisions of the design and/or drawings shall be complied with.
• Cantilever supports shall be adequate.
• Props shall be directly under one another in multistage constructions as far as possible.
• Guy ropes or stays shall be tensioned properly.
• There shall be adequate provision for the movements and operation of vibrators and
other
• construction plant and equipment.
• Required camber shall be provided over long spans.
• When formwork is dismantled, its individual components shall be examined for
damage and damaged pieces shall be removed for rectification. Such examination
shall always be carried out before being used again. Before re-use all components shall
be cleaned of deposits of soil, concrete or other unwanted materials. Threaded parts
shall be oiled after cleaning.
• All bent steel props shall be straightened before re-use. The maximum deviation from
straightness is 1/600 of the length. The maximum permissible axial loads in used props
shall be suitably reduced depending upon their condition. The condition of the steel
shuttering plates shall be examined closely for distortion and defects before re-use.
• In case the height of props exceeds 3.50 meter, the prop shall be provided in multi-
stages.

• Where it is stipulated that the form work shall be paid for separately, measurements
shall be taken of the area of shuttering in contact with the concrete surface.
• Dimensions of the form work shall be measured correct to a cm.
• Centering, and shuttering where exceeding 3.5 metre height in one floor shall be
measured and paid for separately.
• Where it is not specifically stated in the description of the item that form work shall
be paid for separately, the rate of the RCC item shall be deemed to include the cost of
form work.
• No deductions from the shuttering due to the openings/ obstructions shall be made if
the area of each openings/ obstruction does not exceed 0.4 square metre. Nothing extra
shall be paid for forming such openings.
138
• Form work of elements measured under categories of arches, arch ribs, domes, spiral
staircases, well steining, shell roofs, curvilinear folded plates & curvilinear eaves
board, circular shafts & chimneys shall not qualify for extra rate for circular work.

100% payment shall be made after satisfactory complete of work, certified by engineer-
in-charge.
139
3.12 PROVIDING U.C.R MASONRY (Item No. 25-27)

Providing U.C.R masonry in C.M.1 :5 in foundation up to 0.50m above G.L with all leads
and lifts including striking joints, curing etc. complete

The work covered by this item shall consist of furnishing all materials equipment and
labour for providing and laying masonry in foundation or super structure with or without
facework, curing and performing all the foundation necessary and ancillary thereto.
3.12.3 MATERIAL:
3.12.3.1 STONES:
All stones used on the works under this specification shall be obtained from contractor’s
own quarries approved by the Engineer – in - charge. The stones to be used in the masonry
shall be tough, hard, sound and durable, resistant to weathering action reasonably fine
grained, uniform in colour and texture and free from seams, cracks or other defects
which will adversely affect their strength durability or appearance. They shall also be free
from weathered portion and shin.
1 SIZE:
The dimension of the stone shall not be less than 15 cm. on any face. Stones used shall
not weigh less than 35 kg each. Chips however will be used to make the masonry as dense
as possible. The total volume of chips will be 5 to 10 % of masonry.
2 TESTS FOR GOOD STONES:

Besides paras 3.12.3.1 above the stone shall be such as will not absorb water more than
5 % of its weight after keeping it under water for 24 hours
3.12.3.2 CEMENT: -
a) Only Ordinary Portland cement (OPC) 43 grade, shall be used
b) Sampling and testing shall be done as per IS: 3535 of 1989 by and at the expense of the
contractor. No cement shall be used until notice has been given that the test result is
satisfactory. Cement older than 90 days, shall not be used unless the test results the
minimum strength requirements. Cement shall, for his physical and chemical requirement
conform to I.S: 8112-1989 where Ordinary Portland Cement is used or its latest revision.
c) The contractor shall create a suitable and adequate infrastructure for procuring, handling,
storing and conveying bulk cement to batching at site with advance planning of work to
be done in next 15 days, as approved by the Engineer – in – charge. The contractor shall
submit periodical stock return from and daily cement consumption statement in the
Performa prescribed by Engineer – in – charge to monitor cement use in the concrete
work.
140
3.12.3.3 SAND:
All the aggregate shall conform to 383 – 1970, of its latest version and as directed by the
Engineer- in- charge. Sand to be used shall be natural as obtained from the bed and the
Quality: -
a) Sand shall consist of hard, inert, durable and uncoated siliceous gritty materials. It shall
be free from injurious amount of dust, lumps soft and flaky particles, shale, alkali,
organic matter, loam, and other deleterious substances, the maximum percentage of
each of the deleterious substances in sand as delivered.
Limits of deleterious materials: -
i) Coal and lignite 1.0 Percent by weight
ii) Clay lumps 1.0 Percent by weight
iii) Material finer than 75 micron I.S sieve 3.0 Percent by weight
iv) Shale 1.0 Percent by weight
v) Total of percentage of all delirious 5.0 Percent by weight

materials (except Mica)
b) Sand shall be free from injurious number of organic impurities and sand that are
producing a colour (obtained by dissolving 9 grams of chemically pure (cup) ferric
chloride and 1 gram c.p cobalt chloride in 100 ml. of water which 1/3 ml. of
hydrochloric acid has been added) darker than the standard in the test (organic test)
for organic impurities shall be rejected.
Grading.
A) Sand shall be well graded so as to impart good workability and good finishing. Sieve
analysis of natural sand shall conform to the following limits of gradation.
IS Sieve CUMULATIVE PERCENTAGE OF WEIGHT

PASSING THROUGH SIEVE
100 MM. 100
4.75 MM 92 – 100
2.36 MM. 75 – 92
1.18 MM. 55 – 82
600 micro 30 - 64
300 micro 10 – 40
150 micro 3 - 10
141
B) Deviations from the prescribed limits of cumulative percentage retained on sieve 10 mm.
4.75 mm. 2.36 mm. 1.18 mm 600-micron, 300 micron, and 150 micron IS sieves shall be
permitted provided total of such deviations to exceed the percentage retained on 600
microns.
iv) Fineness Modulus: -

a) Sand shall have a fineness modulus between 2.4 to 3.0 subject to the gradation
specified in the preceding paragraph.
b) The modulus shall be computed by adding cumulative percentage of sand retained on
the standard screens. 4.75 mm. 2.36 mm. 1.18 mm. 600 micro, 300 micro, 150 micro,
IS sieves and dividing the sum by 100. Gradation of sand shall be so controlled that
the fineness modulus of at least 9 out of 10 test samples of finished sand shall not vary
by more than 0.10 from the average of 10 samples. Sand having any deviation from
specified range gradation and fineness modulus for shall not be permitted to be used.
Sand having any deviation from specified range gradation and fineness modulus shall
not be permitted to be used in work without written permission of the Engineer – in –
charge.
c) Allowance of Bulkage
• If the sand as obtained from quarry or after its washing is found to be moist,
bulkage will be measured and allowance provided.
• Sand is stacked at site at least for 48 hours before use. Bulkage of such stack
will be measured regularly as directed by the Engineer-in-charge and allowed
according to these observations.
Below 5% NH
5 to 10 5 percent
10 to 15 10 Percent
15 to 20 15 Percent
20 to 25 20 Percent
25 to 30 25 Percent
30 to 35 30 Percent
Testing:-
The following testing frequencies shall be maintained for the same of coarse
aggregates.
Sr.No Name of Test Minimum number of test Specified
1 Gradation for fineness Modulus Daily one test. If test variation of

daily F.M values is more than 0.1
then frequencies may be increased
142
2 Silt Content Daily one test.
3 Moisture Content Daily one test
3 Sp. Gravity and water absorption, Twice in a working season

alkali, aggregate reactivity,
pictographic examination
Storage: -
All sand shall be stored on the site of work in such a manner as to prevent intrusion
foreignmatter.
3.12.3.4 WATER:
1.QUALITY
quantities of silt, organic matter, alkali, salts and other injurious materials
2.TURBIDITY PERMISSIBLE
The turbidity of water for mixing mortar not been more than 2000 parts per million and
shall preferably as low as possible.
3.12.3.5 MORTAR-GENERAL:
1 SPECIFICATION FOR INGREDIENTS:

It shall be seen that the ingredients going to form the finished product of mortar
comply individually with the specifications separately laid out for each of them.
2 TIME FOR USE:

Mortar shall be used in masonry within the time specified for the initial set of
cement which shall not be more than 30 minutes as directed by the Engineer -
in-charge.
3 PROPORTION OF INGREDIENTS:
The proportions of ingredients mentioned in the detailed specifications for each
type of mortar are nominal proportions. The mix proportion is liable to be varied
at the discretion of the Engineer-in-charge to ensure the requisite strength. If
the nominal mix fails to give the requisite strength, the mix shall be varied as
directed by the Engineer-in-charge. The mix proportions stipulated are by
volume. The volume of sand will be directly measured prior to mixing. Volume
of cement shall be reckoned on the basis of 0.034 cum of cement per bag.
4 STIPULATED CRUSHING STRENGTH:
4.1 The stipulated crushing strength of various mortar proportions shall be as below.
143
Mortar mix Cement: Sand Stipulated crushing strength at the
end of 28 days kg/cm 2
1 1: 5 56
2 1: 6 35
3 1: 8 24
• The crushing strength of mortar used in part of Masonry shall not be less than
80% of the final crushing strength, at the end of 28 days.
• In some cases, there is appreciable gain in strength beyond 28 days also. In such
cases if the strength is attained after 45 to 90 days, the masonry shall be
accepted as satisfactory.
4.2 PRELIMINARY LABORATORY TESTS:

Preliminary tests on cubes should be carried out in the laboratory well in advance
of commencement of work.
4.3 a) WORKS TESTS ON MORTAR:

Tests for crushing strength shall be on standard cubes as per relevant Indian
Standard Specifications. For works tests samples shall be taken on the job as and
when directed. Generally, for works test, samples shall be taken for every 100
cum. of masonry and at least once in a day. Materials for the works test (Mortar,
cement, sand as the case may be) shall be supplied by the Contractor free of
cost and collection of samples, casting of cubes, curing and testing shall be
carried out by the Corporation at its own cost.
b) STANDARD OF ACCEPTANCE:
• Not a single sample of work test cubes shall have at the age of 28 days, a
crushing strength less than the stipulated crushing strength of mortar.
• Each sample of work test cubes shall assume to represent 100 cum masonry and
corresponding quantity of masonry showing crushing strength.
• If the crushing strength falls below acceptable limit of the stipulated crushing
strength, then the quantity of masonry represented by these samples will not be
paid for. Defective parts, if noticed shall be removed and redone by the
contractor at his cost.
3.12.3.6 CEMENT MORTAR:
1 PROPORTION:
The mortar shall be obtained by thoroughly mixing together the ingredients in a
mechanically operated mixer.
2 MODE OF MIXING:
• The ingredients of mortar shall be properly mixed in mixers as designed, so as
to positively ensure uniform distribution of all the component material
144
throughout the mass at the end of mixing period.
• After all materials except for the full amount of water in the mixer the mixing
of each batch shall continue for about 1 to 2 minutes depending upon the
revolutions per minutes of the mixer, and experience.
• The minimum mixing period specified above assumes proper control of the speed
of rotation of the introduction of the materials including water.
• The mixing time shall be increased at the discretion of the Engineer-in-
charge when the charging operation fails to produce the required uniformity of
composition and consistency within the batch and from batch to batch.
• The Contractor shall not be entitled for any extra payment of such increase in
mixing time.
• The excessive mixing requiring the addition of water to preserve the required
mortar consistency shall be avoided. If the mixing and charging operations are
such that required uniformity of mortar is obtained in shorter mixing time than
the minimum specified, without sacrifice of needed workability the mixing
time may be shortened under orders of the Engineer-in-charge.
• Mixing shall be done by mechanical means only.
• The sequence of feeding of the ingredients into the mixer shall generally be
as under:
50% of requirement of water. 50% of requirement of sand. Full quantity of cement.
Balance quantity of sand. Balance quantity of water.
3.12.4 MIX VARIATION:

3.12.4.1 MIX VARIATION CLAUSE FOR CEMENT:
Mix variation (cement: sand) shall not constitute an extra item. If the proportion
of cement to sand is varied, an addition or deduction shall be made in the rate of
masonry for the cement used in excess or short of the stipulated requirement of
cement per cubic meter of masonry as shown in table below. For this purpose,
the volume of mortar in masonry shall be taken as shown in column 3 of table
below corresponding to proportions of mortar and the volume of mortar will be
taken to be equal to the volume of the sand before mixi ng.
% Of volume of mortar in Assumed cement content
Sr. No. Proportion of mortar
masonry in Kg. per cum.
1 C.M.--- 1: 8 35 62.5
2 C.M.--- 1: 6 35 83.5
45 107.0
35 100.0
3 C.M.--- 1: 5
45 128.5
3.12.5 MASONRY (GENERAL):

3.12.5.1 The clause under this section shall apply to all types of masonry.
3.12.5.2 STONES TO BE WETTED BEFORE USE:
• All stones, chips etc. shall be clean and free from dust or mud to ensure a good
145
bond with mortar and shall be wetted before being laid. For this purpose, the
stones that are immediately to be used shall be kept sprinkled with good clean
water.
• There shall be a good collection of stones and spauls within easy reach of
masonry to enable proper selection of stone for the individual locations while
laying, and the stones shall be kept continuously replenished.
3.12.5.3 DRESSING OF STONE:

• The stones shall be set in the work as received from quarry after early
knocking of weak corners and edges with a mason's hammer and after cleaning
scales of foreign matter if any.
3.12.5.4 LAYING:
• The stones shall be laid carefully on their natural flat bed so as to break
joints as much as possible.
• They shall be solidly embedded in mortar with close joints. No joints shall
exceed 4 cm. nor shall it be less than 12 mm. in the thickness.
• Chips of stones and spalls shall be wedged in the work wherever necessary to
avoid thick beds of joints of mortar and to give masonry maximum density.
• No dry work or hollow space shall be allowed.
• Every stone, whether large or small shall be set flush in mortar, sh aken and
hammered down by a mallet to sink into it.
• The smaller stones used in the filling shall be carefully selected to fit snuggly
into the interstices between larger ones.
• Mortar to be added to fill the intervening spaces shall be well worked out by
trowel and steel bar.
• Disturbing the mortar during the period of setting shall be avoided. Mortar
joints of top and sides of a layer shall be pressed and brushed over by coir brush
as soon as masonry is laid so as not to leave any loose mortar.
3.12.5.5 (A) BONDING AND BOND STONES:

• For ensuring good bond, masonry shall be finished uneven at the end of the
day's work or at the top surface of the work done in each lift.
• No mortar shall be allowed to remain over the masonry at its top. At the
close of the day's work, all mortar on the top shall be removed.
• Bond stone shall be at least 0.05 Sq. m. face area and shall run back in the
work, at least 60 cm. or the full depth of the work if it is less than 60 cm.
• If the wall be over 60 cm. thick a line of headers overlapping each other at
least 15 cm. shall be laid right through the wall.
A row of vertical headers shall be erected at above 2 m. c/ c bothways so that
there is at least one vertical header for every 4 sq. m. in ever y layer. The
headers shall be at least 60 cm. long.
3.2.5.6 PRECAUTIONS TO OBTAIN DENSE MASONRY:

In order to obtain dense masonry, following precautions shall be taken,
i) Under-pinning shall be avoided after a stone laid as it tends to lift the stone and
146
create air pockets.
ii) Putting chips in the intervening space before filling with mortar shall be
avoided.
iii) Leveling of masonry on the top of the course by use of chips, shall be
avoided. All chips on ends will be driven on one end only, which will help to
squeeze and compact the mortar in the joints.
3.12.5.7 LIMIT ON HEIGHT OF MASONRY TO BE DONE IN A DAY:

• The maximum height of masonry layer that will be allowed to be constructed
at a time shall be 0.6 meter.
• No fresh masonry shall be laid over masonry previously laid within 24 hours
of its laying.
3.12.5.8 WORK IN LINE AND PLUMB:

• The work shall be built square, plumb, curved or battered as may be required
by the design and drawings.
• It shall be carried out in a workman like manner with the aid of molds, templates,
centres etc. which will be provided by the Contractor at no extra cost.
3.12.5.9 QUANTITY OF MORTAR:

• Every effort shall be made to see that proper quantity of mortar is used in the
masonry.
3.12.5.10 SCAFFOLDING TO BE DONE BY CONTRACTOR:

All scaffolding required for the work shall be provided within the rates quoted
for the items of masonry.
3.12.5.11 PROVIDING PLANKWAYS:

Plank walk ways or other suitable arrangement shall be provided at the
Contractor's cost promptly for the use of necessary job traffic over freshly laid
masonry of the day.
3.12.5.12 CURING OF MASONRY:

• All masonry as it progresses shall be kept well watered on the top and sides
for a period of not less than 14 days from the date of build -up place.
• The top of all masonry is to be kept well watered, watering shall be done
carefully so as not to disturb or wash out mortar.
• Where watering is done by manual labour, night shift, if necessary, shall be
arranged for constant watering.
• Masonry shall on no account be allowed to present a dry surface during curing
period.
• Should the mortar perish i.e., become dry through neglect of watering, such
work shall be demolished and rebuilt at no extra cost.
• If the curing arrangement of the Contractor is not satisfa ctory the Engineer-
in-charge may in his discretion engage labour and provide material,
equipment for curing and recover expenditure thus involved from the
147
Contractor.
3.12.5.13 WEAK OR DEFECTIVE MASONRY:

• If any portion of masonry is found to be defective either in materials or in
construction it shall be removed and rebuilt by the Contractor without extra
cost.
3.12.5.14 CLEANING AFTER CONSTRUCTION:

All masonry shall be cleaned after completion.
3.12.5.15 BLOCKOUTS AND SLOTS TO BE PROVIDED BY THE CONTRACTOR

• Block-outs and slots necessary for embedding the foundation bolts and other
embedded parts shall be provided by the Contractor without any extra cost.
3.12.5.16 DAMAGE DUE TO FLOODS, GOVERNMENT NOT RESPONSIBLE:

Any damages done to masonry due to the floods, passing over the work
completed in the previous working season, or caused due to floods during
construction, shall be covered by the rates quoted for the items. No extra claim
shall be entertained for such damages
3.12.6 MODE OF MEASUREMENTS AND PAYMENTS:

• Item shall be measured and paid on cubic meter basis.
• Payment shall be made on the net quantity of masonry arrived at, after deducting
quantities for openings and other class of work from the total volume of
masonry.
• Such deductions shall not apply to the anchor bars, grout holes, bore holes or
weep holes or any other opening not exceeding 100 sq. cm. in cross section.
• The Contractor shall submit the report covering all tests on material,
workmanship, finally laid masonry at required frequencies (The tests prior to
construction (Tests on materials-Stone, Cement, Sand), the tests at the time of
construction (Flow Test of mortar) and tests after construction (90cm Core of
Masonry).
• It should also cover the analysis of the tests and the conclusion for the
acceptance.
• Measurement shall be recorded after satisfactory report. The Engineer-in-Charge
will be responsible to verify and accept the report before accepting the
measurements.
masonry for specified period etc. all complete.
148
Percentage of
Sr. No. Item
Payment

2 100%
Or measurement of portion for Final

3.12.7.1 PREPARATION OF FOUNDATION OR BASE FOR MASONRY LAYING:
1 CLEANING OF FOUNDATIN WITH WATER JET:
The foundation surface shall be thoroughly cleaned off from all loose material, including
all chips, dirt etc. This shall be done with the help of stiff brooms and waterjet.
2 LAYING OF MASONRY IN DAY-TO-DAY WORK:
Before laying of masonry, the surface of masonry in day-to-day work shall be cleaned
with waterjets so that surface is thoroughly cleaned and wetted out pools of water shall
be avoided. The cost of such cleaning shall be covered by the unit rate for the item of
masonry.
TREATMENT OF HARDENED MASONRY SURFACE:
Masonry surface over which the floods have not passed and have remained exposed for
a long time such that, the new masonry cannot be integrated with the previous one, shall
be prepared in same manner as indicated for foundations. Before starting the new layer
of masonry over the old one, the mortar shall be scraped from the joints in lower layer to
a depth of at least one layer.
Masonry surface over which the floods have passed and have remained exposed may
require removal f some portion thereof, the of which shall be decided by the Engineer in
charge.
The dismantling and reconstruction work involved shall, however not be paid for and
deemed to have been covered under unit rates.
3.12.7 UNCOURSED RUBBLE MASONRY

Uncoursed rubble masonry in cement mortar of specified proportion including striking
joints, scaffolding watering etc. complete and shall be used for faces against which earth
work rests. i.e., unexposed faces of abutment, wings etc.
149
3.12.7.1 DRESSING AND SIZE:
Stones to be set in the work shall be as received from the quarry after merely knocking
off weak corners and edges with masons hammers. In the case of face stones all the sides
of the stones shall be dressed in straight lines and all the sides shall be in one plane.
3.12.7.2 FACE STONES:

The face stones shall be selected from the mass of quarry stones for their greater size,
‘good beds close grain, and uniform color. Individual stones shall have thickness and and
width of not less than 15cm in its thickest part and no stone shall be less in length than11/2
times its height.
3.12.7.3 THROUGH STONES:

One though stone shall be provided per half square metre of facing evenly distributed,’
they shall be about 0.03 sq.mtr.in face area and shall have a tailing of the full width of
the masonry when the width is 60 cm. or less. If the wall or masonry be over 60 cm. in
width, line header overlapping each other by at least 15cm.shall be laid right through the
wall from face to back. The length of the interior headers shall not be less than 45cm.and
their average cross-sectional area shall not be less than 0.025 sq.m. Face header shall
distinctly be marked on its face
3.12.7.4 VERTICAL HEADERS:
For massive work with a width of a metre and above vertical headers 45 cm. long or
depth of two course whichever is more shall be provided at the rate of one for every sq.
metre of area in plan. For every course new set of headers shall be introduced at this rate
in a staggered pattern. Their average sectional area shall not be less than 0.03sq.m.
3.12.7.5 HEARTING AND BACKING STONES:

In walls of 60 cm and less about 30 percent of the stones shall not be less than 0.010 cum
and for thicker walls about 33 percent of stones shall not be less than 0.015 cum.
3.12.7.6 QUOINS:
The quoins shall be of selected stones and shall be provided as directed by the Engineer
–in charge. The faces of quoins shall be rough tooled or provided with the same type of
dressing as that of the face stones or as directed.
The face stone shall be laid without any pinning on the exposed face. . In each course the
headers or lines of headers as the case may be, shall be in position at specified intervals
and with specified lap where such laps are required before the masonry of the layer is
commenced to ensure that they are being laid properly and in required numbers and
intervals. They shall be embedded in mortar as masonry in that layer progresses. Quoins
shall be laid stretcher and header wise as seen on each face and shall correspond the
arrangement of quoins in the same course.
3.12.7.7 JOINTS:
No face joint shall exceed 2 cm.
150
STRIKING JOINTS:
The face joints should be properly struck while the mortar is fresh. Joints which cannot
be so struck at time of laying, shall be prepared for it by raking joints to a depth of not
less than 2 cm. when the mortar is fresh. These joints should be properly cleaned of loose
particles, wetted thoroughly and filled with good fresh cement mortar 1:3 and finished
off by being toweled smooth.
3.12.7.8 RATE OF RAISING MASONRY:

The rate of raising uncoursed rubble masonry brought up in uniform levels shall be
limited to a height of 60 cm. per day. But no fresh course shall be laid over masonry
previously laid within 24 hours laying.
3.12.7.9 ITEM SHALL INCLUDE:

1) Uncoursed rubble masonry laid in cement of specified proportion built in any position
to any height and to lines, level, curves and batter shown in the plans or as ordered by
the Engineer – in – charge, including quoins, headers etc. and striking joints and
curing.
2) Erecting and removing all scaffolding, labour and inspection of the work including
compensation for any injury damage etc.
3) Dewatering to allow construction in the dry and proper setting of masonry unless
separately provided for in the tender etc.
4) Clearing the site round the masonry.
5) All labour, use of tools, material and items incidental to satisfactory completion of the
item.
3.12.8 MODE OF MEASUREMENTS AND PAYMENT:

The item will be measured and paid on cubic metre basis.
Payment at the rate of 2 % shall be withheld in running payment Engineer - in- charge,
shall inspect the work in relation to finishing, level and line of masonry laid, and release
such withheld payment suitably if he is satisfied with the work of finishing of the item.
151
3.13 PROVIDING KHANDKI (Item No. CC 28)

Providing Khandki facing to the face of masonry with Pointing in C M 1:2 including
finishing to the required shape and slope with necessary scaffolding, curing etc. complete
with all leads and lifts. ( Khandkis are of the size 20cm in 20 cm. No mortar for pointing
is taken into account only face pointing of joint is considered)

This item includes providing Khandki facing to face masonry including all material
labour and equipments required for the work.
3.13.3 MATERIAL
3.13.3.1 STONES FOR FACE WORK.

Stones generally be quarried with clean faces and sharp edges all round and shall be of
such character that it can be brought to such lines and surfaces, whether curved or plane
as may be required Size and shape of stones shall be as per requirements. Stones to be set
in the work shall be as received from the quarry after merely knocking off weak corners
and edges with masons hammer. All the sides of the stones on the face shall be dressed
in straight lines and all the sides shall be in one plane so as to have the vertical and
horizontal sides perfectly straight parallel and right angles to adjacent side. No stone shall
be less than 400 square centimeter on the face. The beds, sides and top shall be square to
the face and rough tooled to at least 2.5 cm on the face .to afford proper bearing,
Individual stones shall have a width of not less than 20cm in its thickness part and no
stones shall be less in width than height and less in length than 1.5 time its height.
3.13.3.2 KHANDKI MASONRY FOR FACE WORK

The Khandki masonry for face work shall be provided to the exposed faces of structure
on water side i.e., to the waterside of abutment wings and piers from foundation to top.
3.13.3.3 BOND STONES.

For good bond stones shall be provided at the rate of 1 per metre of each course of the
face work. They shall have a tail of at least 50 cm.
3.13.3.4 QUOINS.
The quoins shall be formed of stones at least 50 cm long and shall be laid header and
stretcher alternately. They shall be laid square on the beds, which shall be neatly dressed
to present nearly square bedding.
3.13.3.5 JOINTS.
The joint in the face work shall not be more than 1cm and stone shall be arranged to break
joints as much as possible and long vertical lines of joint shall be avoided.
152
3.13.3.6 POINTING.
Pointing to all of Khandki faces shall be done as per the specifications of pointing.
3.13.4 MEASUREMENTS AND PAYMENT.

Face work shall be paid for under item, irrespective of mortar proportions for the masonry
shall be based on the finished exposed surface area of facework.
The cost of pointing is covered in the unit rate of Khandki it shall not be paid separately.
153
3.14 PROVIDING AND LAYING DRY STONE RUBBLE MASONRY
(Item No. CC 29)
Providing and laying dry stone rubble masonry excluding pointing and royalty of material
etc. complete

This item includes providing and playing dry stone rubble masonry including all
materials, labour and equipment
3.14.3 MATERIAL
3.14.3.1Stones for dry rubble masonry shall be sound, hard, dense and durable and resistant to
weathering action reasonably fine-grained uniform in colour and texture and free from
seams, cracks and other defects which would adversely affect their strength durability
and appearance.
3.14.3.2 SIZE.
The dimension of the stone to be used shall not weight less than 35kg each. Chips
however will be used to make rubble masonry as dense as possible. The total volume of
chips will be 5 to 10% of masonry.
3.14.3.3 Test for good stone.

Before any quarry for at stone is approved it shall be seen that besides satisfying the
specification mention in para 1.2.1. above stone shall be such as will not absorb for water
more than 5% of its weight after keeping it under water for 24 hours.
3.14.4 SEQENCE OF EXECUTION

1 In appearance dry rubble masonry will be like squared rubble built to courses. Each
course shall we built through to entire thickness of the wall without mortar but with
chips and spalls. The stone shall be rough dressed to secure the maximum bedding
surface without unduly reducing the size of stones. The largest stone shall be used in
a such construction, the larger being used in the lower courses.
2 Dry stone walling shall not have a face batter stiffer than 1:12 and until otherwise
specified batter shall be 1:4. The back of the wall shall be vertical Foundation as well
as the courses must be at right angles to the face batter and not horizontally.
3 Through or Bond stones shall be provided in each course at intervals of 2 metres. Bond
or through stones shall be of the full height of the course in which they are used and
shall be as broad as possible. All bond through stones shall separately stacked before
use and face marked with paint so that they can be identified having been built into
the wall.
154
4 Where ordered by Executive Engineer, long length of dry rubble walls shall be divided
with panels separated from one another by short length of walls 2 metre in cement
motor at every 10m. interval in order to confine damage if any only to the panels
affected and thereby to minimize the repairs there to.
5 Weep holes shall be provided in dry stone walling when built against Earth or hill
slopes subject to saturation by surface or ground water flow.

Dry rubble masonry shall be measured in cubic metres.

The unit for payment of this item shall be one cubic metre.
155
3.15 PROVIDING POINTING (Item No. CC 30)

Providing pointing with cement mortar for stone masonry including raking joints
scaffolding, curing etc complete.

This item includes materials, labour, equipments required for pointing to stone masonry
with cement mortar mentioned in the item including raking joints, scaffolding and curing.
3.15.3 MATERIAL
PROPORTION OF MORTAR:
All pointing shall be done with cement mortar 1:3 unless otherwise specified the cement
shall be ordinary Portland cement procured by the contractor at his own risk and cost.
The sand to be used shall be fine. It shall pass through No. 16 mesh. A.S.T.M. (I.S.120).
The sand shall confirm in all respects to specification under item on.51.
3.15.4 RAKING JOINTS.

The joints in masonry to be pointed shall braked square for a minimum depth of 4 cm.
within 24 hours of laying of masonry. In special circumferences this period may be
relaxed 48 hours. The refilling and pointing shall be done within 3 days of raking of the
joints so as to ensure good adhesion between the two mortars. If the racking is not done
within the period specified above, the Engineer in charge may engage labours to racking
joints and recover the cost of thereof from the contractor.
3.15.5 CLEANING JOINTS:

Before pointing, the joints shall be regularly cleaned off any dirt or loosely adhering
cement or mortar and washout properly and thoroughly.
3.15.6 FILLING JOINTS:

The joint Sal then be field which cement mortar 1:3 unless otherwise specified. Which
shall be regularly rammed and caulked into the joints. The pointing mix shall neither be
too dry nor too wet. The mortar shall have just enough water so that it will stick together
on being moulded into a ball by a slight pressure of the hands but will not leave out free
water where in so pressed and will leave the hand damp. Pointing shall be carried out as
rapidly as possible and not touched again after the motor has once begun to set.
3.15.7 FLUSH POINTING:

The joints shall be filled with cement mortar which shall be properly rammed and caulked
into the joints. The pointing mix shall neither too dry nor too wet. The mortar shall have
just enough water so that it will stick together on being moulded into a bail by slight
pressure of a hand but will not leave free water when so pressed n the joints will leave
156
the hands damp. No line shall be pressed on the joints but the joints shall instead be
merely rubbed smooth with the" NAYLA" as soon as the mortar has begun to set. The
extra mortar on the edge shall be carefully scraped off to give a neat appearance. Pointing
shall be carried out as rapidly as possible and not touched again after the mortar has once
begun to set.
3.15.8 FINAL FINISH OF JOINTS:

The joint shall be neat, defined, regular and of a uniform width.
The work pointed should be kept wait for 14 days after pointing is completed.
3.15.9 MEASUREMENT AND PAYMENT:

The cost of pointing is not covered in the unit rate of U.C.R or C.R masonry. it should be
paid separately on the basis of sq.min pointing item. The cost of pointing is covered by
the units of rate of khandki, it should not be paid separately.
157
3.16.1 DESCRIPTION OF ITEM (Item No. CC 31)
Providing and constructing coursed rubble masonry II sort in C.M 1:4.5 for superstructure
with all leads and lifts including striking joints, curing complete excluding pointing.

This item includes constructing Course rubble masonry second sort in cement mortar of
specified proportion including scaffolding etc. complete.
Specification under section for item no.51of masonry. shall apply in all pertinent and
particulars C. R. Masonry 2 nd sort shall also comply with the following in addition
3.16.3 MATERIALS
3.16.3.1 STONES:
All stones used on the works under these specifications shall be obtained from
contractor’s own quarries approved by the Engineer – in - charge. The stones to be used
in the masonry shall be tough, hard, sound and durable, resistant to weathering action
reasonably fine grained, uniform in colour and texture and free from seams, cracks or
other defects which will adversely affect their strength durability or appearance. They
shall also be free from weathered portion and shin.
1 SIZE:
as possible. The total volume of chips will be 5 to 10 % of masonry.
2TEST FOR GOOD STONES:

Besides paras 1.2.1 above the stone shall be such as will not absorb water more than 5
% of its weight after keeping it under water for 24 hours
3.16.3.2 CEMENT: -
contractor. No cement shall be used until notice has been given that the test results are
Performa prescribed by Engineer – in – charge to monitor cement use in the concrete
work.
158
3.16.3.3 FINE AGRREGATE:
General: -
All the aggregate shall conform to 383 – 1970, of its latest version and as directed by the
Engineer – in – charge. Sand to be used shall be natural as obtained from the bed and the
Sand aggregates will be tested as per provision of concrete section.
Quality: -
be free from injurious amount of dust, lumps soft and flaky particles, shale, alkali, organic
matter, loam, and other deleterious substances, the maximum percentage of each of the
deleterious substances in sand as delivered to the mixer shall not exceed the following
values.

b) Sand shall be free from injurious number of organic impurities and sand that are
producing a colour (obtained by dissolving 9 grams of chemically pure (cup) ferric
chloride and 1 gram c.p cobalt chloride in 100 ml. of water which 1/3 ml. of hydrochloric
acid has been added) darker than the standard in the test (organic test) for organic
Grading.

100 MM. 100
4.75 MM 92 – 100
2.36 MM. 75 – 92
1.18 MM. 55 – 82
159
600 micro 30 - 64
300 micro 10 – 40
150 micro 3 - 10
B ) Deviations from the prescribed limits of cumulative percentage retained on sieve 10

mm. 4.75 mm. 2.36 mm. 1.18 mm 600 micron, 300 micron, and 150 micron IS sieves
shall be permitted provided total of such deviations to exceed the percentage retained on
600 microns.
iv ) Fineness Modulus :-
a) Sand shall have a fineness modulus between 2.4 to 3.0 subject to the gradation specified
in the preceding paragraph.
b) The modulus shall be computed by adding cumulative percentage of sand retained on
the standard screens. 4.75 mm. 2.36 mm. 1.18 mm. 600 micro, 300 micro, 150 micro, IS
sieves and dividing the sum by 100. Gradation of sand shall be so controlled that the
fineness modulus of at least 9 out of 10 test samples of finished sand shall not vary by
more than 0.10 from the average of 10 samples. Sand having any deviation from specified
range gradation and fineness modulus for shall not be permitted to be used. Sand having
any deviation from specified range gradation and fineness modulus shall not be permitted
to be used in work without written permission of the Engineer – in – charge.
Specification of concrete section is applicable for Allowance of Bulkage.
Testing: -
The following testing frequencies shall be maintained for the same of coarse aggregates.
Sr. No Name of Test Minimum number of tests
Specified


160
Storage: -
foreign matter.
3.16.3.4 WATER:
quantities of silt, organic matter, alkali, salts and other injurious materials
3.16.4 DRESSING AND SIZE

3.16.4.1 Face stones
The stones received from quarry shall be dressed so as to have the vertical and horizontal
sides perfectly straight parallel and at right angles to adjust sides. The four sides of the
stone of the face shall lie in one plane. Bushing on the face of the stones shall not project
more than 4 cm. The beds and tops shall be square to the face rough tooled at least 8 cm.
from the face. The side vertical joined face shall be square to the face and rough tooled
to at least 4cm.from the face. The face shall have depression below the plane of the sides.
All the khandki stone shall be more in breadth than in height and shall run back in to the
masonry. for not less than 1.5 times then height. 30% of the khandki shall have tailing of
twice their height, 30% of these face stones shall not be less than 0.02 cum.
The height of the khandki shall not be less than 20cm or as specified for the particular
item. These khandki shall be provided for the interior face also when it is to remain
exposed or so specially provided.
3.16.4.2 HEARTING AND BACKING STONES.

When the interior face is to be plastered or otherwise permanently remaining covered
backing stones shall be as specified for U.C.R masonry. Hearting and backing stones
shall be as big as possible .30% of this shall not be less than 0.010 cum. for wall 50 cm.
30% of that shall not be less than 0.015 cum.
3.16.4.3 QUOINS
The coins shall be of selected stone and shall normally be of the same height and that of
the course in which they are to be used. If the plans show height of two courses they shall
be provided accordingly. The faces of quoins shall be rough tooled or hammer dressed as
directed by the Engineer in charge. A chisel draft of about 40mm .shall be provided on
its side of the exposed corners.
The beds and tops shall be dressed square to the face and rough tooled to 10 cm from the
face and vertical joints similarly dressed to 4 cm from the face. The length of the quoins
shall not be less than twice their height or 44cm whichever is more on the longer face not
less than their height for the shorter face. In the embedded portion the length of the sides
shall not be less than that of the exposed side opposite by more than 6 cm for the longer
side and 5cm for the shorter side.
161
3.16.4.4 THROUGH STONES.
The height of through stones shall be the full height of the course and width shall not be
less than the height. The face, beds and joints shall be dressed similar to khandkis.
They shall be about 0.05 sq.m.in. face area and 0.03 sq.m in average cross-sectional area
and shall have a tailing of the full width of the masonry when the width is 60 cm or less
if the masonry be ever 60cm in width, a line of header overlapping eachother by at least
15cm shall be laid right through the wall from the face to the back. The length of the
interior headers shall not be less than 44 cm and their average cross-sectional area shall
not be less than 0.03 sqm. Face header shall be distinctly marked on its face.
3.16.4.5 VERTICAL HEADERS.

For massive work with a width of a metre and more vertical headers 44cm long or depth
of two course whichever is more shall be provided. The average sectional area of it should
not be less than 0.03 sq.m.
3.16.5 CONSTRUCTION
The stones shall be laid to horizontal courses of not less than 14cm. The stones in each
course shall be of equal height, two stones may be used for height in one course up to
50% of the face area. All courses shall be of the same height and less otherwise specified
or directed by the Engineer in charge. But no course shall be thicker than any course
below it unless otherwise shown on the plans or directed the heights of different courses
shall be predetermined and shall match with the corresponding course in other parts of
the structures
Khandki stones shall be provided for face remaining exposed. backing shall be off UCR
masonry when unexposed or plastered
The through shall be placed 1.5 metre apart clear in every course before starting the
construction of that course and finally embedded in the course.
Vertical headers shall be provided in the case of massive masonry where the thickness of
the masonry is one or more at the rate of one for every sq metre of area in plan. For every
course a new set of headers shall be introduced at this rate in a staggered pattern.
The quoins shall be laid header and stretcher wise as seen on each face of the wall and
shall correspond to the arrangement of quoins in the same course.
The face of masonry to be plastered or remaining permanently un exposed shall conform
to U. C. R masonry unless otherwise directed.
The thickness of joints shall not exceed 12 mm where pointing is to be done, the joints
shall be racked to a depth of not less than 10 mm when the mortar is green.
The quantity of mortar for one cubic metre of thin and massive masonry shall range from
0.28 cum to 0.33cum and from 0.46 to 0.48 cum for water retaining masonry.
162
3.16.5.1 RATE OF RAISING MASONRY.
The rate of raising masonry in cement mortar shall be limited to 60cm per day. But no
fresh course shall be laid over masonry previously laid within 24 hours of its laying for
cement mortar.
3.16.5.2 STRIKING JOINTS.
The joints of the non- exposed face when pointing is not to be done shall be neatly struck
when the motor is green. Joints which cannot be so struck at the time of laying shall be
prepared for by racking joints to a depth of not less than 10 mm when the mortar is fresh.
These joints shall be properly cleaned of loose particles wetted thoroughly and filled with
good fresh cement mortar 1.3 and finished off by trowelling smooth.
3.16.5.3 ITEM TO INCLUDE.
1) Course rubble masonry 2nd short laid in cement mortar of specified proportion built in
any position to any height or depth and lines level curves and batters shown on the plans
or as ordered by the Engineer in charge including striking joints, racking out joints and
curing for the specified period. Chisel drafting chamfering and raising the stones to lines
shapes and curves shown on the working drawings, cutting grooves etc for fixing frames
fixtures etc headers and rough tooled quoins are also included
2) Erecting and removing all scaffolding ladders and use of plants required for excavation
of the item satisfactorily compensation for any injury damage etc
3) Inspection facilities
4) Dewatering unless separately provided for in the tender
5) Cost of all labour materials use of tools and equipments and incidental items required for
satisfactory completion of the item.
6) Clearing site around the masonry.
3.16.6 MODE OF MEASURMENT AND PAYMENT.

The contract rate shall be for unit of one cum of masonry completed in all respects in
place and accepted. The quantity of coursed rubble masonry to be paid under this item
shall be number of cum of finished work and limiting dimension shall not exceed those
shown on the plans or as ordered in writing by the Engineer in charge.
Dimensions shall be measured and individual quantities calculated correct to 2 places of
decimals of a metre and cubic metre respectively.
Battered tampered or curved portions shall be measured net.
Payment at the rate of 2% shall be withheld in running payment. Engineer in charge
inspect the work relation to finishing level and line mortar /concrete laid and release such
withheld payment suitably if he is satisfied with the work of finishing of the item.
163
3.17 CUTTING RECTANGULAR GROOVES (Item No. CC 32)

Cutting rectangular grooves of size 10cmx10cm in stone masonry including cleaning
pointing etc .to facilitate smooth working of needles etc. Compute.

This item includes all material, labour, equipment required for cutting rectangular
grooves of in stone masonry including cleaning, pointing to facilitate smooth working of
needles.
3.17.3 MATERIAL:
Sand and cement for mortar shall be as specified in the item of masonry 3.12.3
3.17.4 SEQUENCE OF EXCAVATION:

After completion of UCR masonry of piers abutments vertical grooves shall be cut by
mason –I class of the mentioned size in the item. The grooves so cut shall be in plumb
and finished. Pointing shall be done to facilitate smooth working of needles.
3.17.5 MODE OF MEASUREMENTS:

Length of the grooves shall be measured in running metres. This includes cutting cleaning
and pointing

The unit for payment of this item shall be one Running metre.
164
3.18 PROVIDING AND LAYING ROUGH DRESSED CUT STONE
COPING (Item No. CC 33)

Providing and laying rough dressed cut stone coping 23 cm. thick in C.M. 1:5 excluding
cement pointing but including watering with lead 50 m. and lift up to 1.5 m., excluding
royalty of material etc. complete.

This Specifications covers the requirements for Providing and laying rough dressed cut
stone coping 23 cm. thick in C.M. 1:5 excluding cement pointing but including watering
with lead 50 m. and lift up to 1.5 m.

3.18.3.1 Stone
Types
The common types of natural building stones which are generally used are, granite and
other igneous rocks, lime stone (including marble), sandstone, etc. For the properties of
these types of stones reference may be made to IS 1123: 1975. Stone shall be sound and
free from seams, cracks, or any other defects. All stones shall be same colour as far as
possible. Mortar shall conform to the specification under section CC.
Quality
All stones used for building purposes shall be strong, hard and durable as indicated in
3.12.3
Strength
The strength of building stones should be adequate to carry the loads imposed. For
ashlar and coursed rubble masonry, the strength shall be as worked in accordance with
IS 1905: 1987, taking into account, the appropriate crushing strength of stone as given
in Table 1, and also the type of mortar used. For random rubble masonry, the strength
value shall be specified on the basis of local experience.
165
NOTE -The sources of information are: for(i) IS 3316: 1974, for (ii) Bombay PWD
handbook: for (iii), (iv) and* (v) DIN 1053: 1952 ‘Wall masonry and design
execution’: and for (vi) IS 3620: 1979.
Durability
The stone shall be free from defects like cavities, cracks, flaws, sand holes veins, patches
of soft or loose materials, etc. The percentage of water absorption (see IS 1124: 1974 for
the method of test) shall generally not exceed 5 percent. Generally, the stone should not
contain crypt0 crystalline silica or chert, mica or any other deleterious material like iron
oxide, organic impurities etc.
TEST FOR GOOD STONES
Before any quarry for a stone is approved, it shall be seen that besides satisfying the
specification mentioned, the stone shall not absorb water more than 5% of its weight after
keeping it under water for 24 hours.

• The coping shall be dressed to correctly to the shape and dimension shown in the
detailed drawings or as directed by the Engineer.
• The coping stone shall be of full width and dressed as specified in the item on the
exposed faces and their joints.
• The other exposed faces of the stone blocks shall be rough tooled.
• The length of the coping stone shall not less than 30 cm. The length of closer shall not
be less than 25 cm.
• All coping shall be dowelled or cramped. String courses shall tail at least 250 mm into
the work and shall be throated on the underside.
• The coping stone shall be laid full in mortar and the joints with the masonry
underneath shall be finished neatly as specified for the masonry. The joint in the fine
tooled, close punched and chisel dressed coping shall be 1.5mm and those in the rough
tooled coping shall be 3mm.
• The joints of the coping shall break joint with those in the masonry.

• The dimensions shall be measured square over all chamfers, throating and mouldings.
The contract rate shall be for one cu. m. It may be alternatively per running meter if
mentioned in the abstract when the shape and dimensions of width and thickness are
mentioned in the special provisions or shown in the drawings. The length shall be then
measured along the centre line correct up to 5mm.
• The Contractor shall submit the report covering all tests on material, workmanship,
finally laid masonry at required frequencies.
• Measurement shall be recorded after satisfactory report. The Engineer-in-Charge will
be responsible to verify and accept the report before accepting the measurements.
166
• The quantity measured shall be paid only after removal of scaffolding and refilling
any holes remained due to scaffolding by concrete at contractor's risk and cost and
curing the masonry for specified period etc all complete.
• The item will be measured and paid on cubic meter basis.
• Payment at the rate of 2% shall be withheld in running payment.
• Engineer-in-charge shall inspect the work in relation to finishing, level and line of
masonry laid, and release such withheld payment suitably if he is satisfied with the
work of finishing of the item.
167
3.19 COLGROUT MASONRY (Item No. CC 34)

Providing cogroup masonry in C.M.1:3 (43%) proper packing rubble and of required
shape and quality with the colgrout at required pressure with all leads and lifts etc.
complete

(i) The work covered by this item shall consist of furnishing all materials equipment and
labour for providing and laying colgrout masonry in foundation or super structure
including formwork scaffolding, curing and performing all the function necessary and
ancillary thereto.
(ii) Installation of all embedments (supplied free of cost by Department) stand included
in the item.
3.19.3 MATERIAL:
3.19.3.1 STONES: All stones used on the works under this specification shall be
obtained from contractor’s own quarries approved by the Engineer – in - charge. The
stones to be used in the masonry shall be tough, hard, sound and durable, resistant to
weathering action reasonably fine grained, uniform in colour and texture and free from
seams, cracks or other defects which will adversely affect their strength durability or
appearance. They shall also be free from weathered portion and shin.
SIZE:
as possible. The total volume of chips will not be less than 15 % of the volume of
masonry.
TEST FOR GOOD STONES:
The stone shall be such as will not absorb water more than 1.5 % of its weight after
keeping it under water for 24 hours.
The specific gravity of stones shall generally be more than 2.80.
3.19.3.2 CEMENT: -
contractor. No cement shall be used until notice has been given that the test result is
168
proforma prescribed by Engineer – in – charge to monitor cement use in the concrete
work.
3.19.3.3 SAND:
i) General: -
All the aggregate shall conform to I.S 383–1970, of its latest version and as directed by
the Engineer–in– charge. Sand to be used shall be natural as obtained from the bed and
the maximum size shall be limited to 4.75 mm.
Sand aggregates will be tested as per provision of concrete section.
Quality: -
be free from injurious amount of dust, lumps soft and flaky particles, shale, alkali, organic
matter, loam, and other deleterious substances, the maximum percentage of each of the
deleterious substances in sand as delivered to the mixer shall not exceed the following
values.

b) Sand shall be free from injurious number of organic impurities and sand that
are producing a colour (obtained by dissolving 9 grams of chemically pure (cup) ferric
chloride and 1 gram c.p cobalt chloride in 100 ml. of water which 1/3 ml. of hydrochloric
acid has been added) darker than the standard in the test (organic test) for organic
Grading.
169
100 MM. Nil
4.75 MM Nil
2.36 MM. 10 –25
1.18 MM. 25 – 45
600 micro 30 - 64
300 micro 75 – 90
150 micro 90 - 97
iv ) Fineness Modulus :-
a) Sand shall have a fineness modulus between 2.4 to 3.0 subject to the gradation specified
in the preceding paragraph.
b) The modulus shall be computed by adding cumulative percentage of sand retained on the
standard screens. 4.75 mm. 2.36 mm. 1.18 mm. 600 micro, 300 micro, 150 micro, IS
sieves and dividing the sum by 100. Gradation of sand shall be so controlled that the
fineness modulus of at least 9 out of 10 test samples of finished sand shall not vary by
more than 0.10 from the average of 10 samples. Sand having any deviation from specified
range gradation and fineness modulus for shall not be permitted to be used. Sand having
any deviation from specified range gradation and fineness modulus shall not be permitted
to be used in work without written permission of the Engineer – in – charge.
Specification of concrete section is applicable for Allowance of Bulkage.
v) Testing: -
The following testing frequencies shall be maintained for the same of coarse aggregates.
Sr. No Name of Test Minimum number of tests
Specified

170
vi) Storage: -
foreign matter.
d)CRUSHED SAND:
The contractor may be permitted to use crushed sand obtained by crushing acceptable
quality of stone. The crushed shall however satisfy all requirements specified above.
3.19.3.4 WATER:
Water used for making mortar shall be reasonably clean and free from objectionable quantities
of silt, organic matter, alkali, salts and other injurious materials.
3.19.3.5 COLGROUT SLURRY(GENERAL):
QUALITY OF INGREDIENTS:
It shall be seen that the ingredients going to form the finished product of Col grout
complies individually with the specifications separately laid out for each of them. As
state din its relevant paragraph.
PROPORTIONS OF INGREDIENTS:
The proportions of ingredients for the Col grout slurry mentioned for the different items
are by weight.
The Col grout slurry shall be obtained by thorough mixing together the ingredients in
specified proportions by weight in a mechanical mixer. The proportions of ingredients of
slurry shall be decided by Engineer – in charge on weight basis. All the ingredients shall
be matched by weight using weighing arrangements which shall be approved by
Engineer- in charge at contractor’s cost.
3.19.3.6 ADMIXTURE:
The contractor shall also add in the manner directed without any extra class to the Col
grout slurry and admixtures like the pozzolanic materials fly ash, surkhi or chemical
admixture etc. Procured by the Contractor. The amount of cement from the contractor’s
mix reduce don account of addition of admixture shall be counted for by way of reduction
in the rate of colgrout masonry item as provided under the mix variation clause at Rs.
.............. per Kg.
3.19.4 STEEL FORM WORK:

a) GENERAL:-
Form work made of only steel to confine the Cogrout Masonry and shape it to the required
line shall be used whenever ,necessary .The form shall have sufficient strength and
171
rigidity to hold colgrout masonry and to withstand the pressure of colgrout slurry without
excessive deflection from the prescribed lines. More so when the slurry is injected. The
contractor shall have to get the design and drawing of the centering, approved from the
Engineer- in Charge before erection.
Formwork mad upon only steel shuttering will be allowed .It should be free from
warping and is fabricated true to line &shape .The inside surface shall be clean .rigid ,
watertight and smooth. Suitable devices shall be used to hold corners. Adjacent ends and
edges of panels of other forms together in accurate alignment.
b) REUSE OF FORMS ETC:

Form required to be used more than once shall be maintained in serviceable condition
and shall be thoroughly cleaned and smoothened before reuse. Where metal sheets are
used for lining forms, the sheet shall be placed and maintained on the forms with
minimum number of wrinkles, lumps and other imperfections. All forms shall be checked
for shape and strength before reuse.
c) ERECTION AND REMOVAL OF FORMS:

i) Before placing Colgrout Masonry the surface of all forms shall be oiled with a suitable
nonstaining oil such as raw linseed oil so as to prevent striking of Colgrout and to
facilitate the removal of form
ii) The Oil shall cover the form fully and evenly without excess over-drip. Care shall be
taken to prevent oil from getting on the surface of the construction joints and on
reinforcement bars. Special care, shall be taken to oil thoroughly the form strips for
narrow groves so as to prevent swelling of form and the consequent damage to Colgrout
masonry prior to or during removal of form immediately before Colgrout Masonry is
place. Cared shall be taken to see that all forms are in proper alignment and the supports
and fixtures are thoroughly secured and tightened.
iii)Where forms for continuous surface are placed in successive units, the forms shall fit
tightly over the completed surface so as to prevent leakage of slurry from the colgrout
Masonry and to maintain alignment of the surface.
iv) Form shall be left in place until the removed is authorized and shall then be removed
with care so as to avoid injury to Colgrout Masonry.
v)Removal of form shall never be started until the colgrout is thoroughly set and hardened
adequately to carry its own weight. Besides the live load which is likely to come on the
work. During constructions. The length of time for which the forms shall remain in place
shall be decided by the Engineer- in charge. With reference to weather conditions shape
and position of the structure, or structural member and the nature and amount of dead and
live load in normal circumstances from shall be struck after the expiry of 48 hours from
injection of colgrout mortar.
In no case shall forms be removed until there is assurance that removal can be
accomplished without damaging the Colgrout masonry surface. Heavy load shall not be
permitted until after the Colgrout masonry has reached its designed strength. The forms
shall be removed with great caution and without harming the structure by throwing heavy
forms upon the floor.
172
3.19.5 MODE OF MIXING
A) Colgrout slurry shall be obtained by thoroughly mixing the mechanically worked double
drum mixer, the constituents in the specified proportion to be added in the sequence as
directed by the Engineer- in Charge from time to time. The mixer to be used for colgrout
slurry shall be double drum colloidal mixer. This arrangement shall be such so as to
remove air particles from cement and water shall be 15 sec. only. The speed rating of disc
should be 1500-2000 r.p.m. and exit pressure of colgrout slurry shall be 1.4 to 7.5 Kg/cm2
Total mixing time for the complete cycle shall be 6 0 sec. to 90 sec.
B) WATER FOR COLGROUT SLURRY :

The quality of water to be used for the mixing for colgrout slurry shall be as specified by
the Engineer-in – Charge from time to time depending upon the quality of sand and
cement to be used and will be generally as under for the weight of cement in the saturated
surface dry conditions of materials.
Standard Colgrout Bathes
Ratio of cement to sand Average water cement ratio Water contents/ 50Kg
cement in litres.
1: 3 0.85 38.47
C) TIME FOR USE:

Colgrout slurry shall be used in masonry within the time specified for the initial set or as
directed by Engineer-in-Charge. Any colgrout slurry which has not been used within the
time specified or as directed by the Engineer- in Charge. Or slurry which has set or
hardened shall be considered unfit for use and removed from work site as the cost of the
contractor and no claim can be entertained on this account.
D) CURING:
All colgrout masonry as it progresses shall be kept continuously watered on the entired
surface for a period of not less than 21 days from the date of its being laid. Where watering
is done by manual labour night shifts, shall be arranged for constant watering Colgrout
masonry shall, on no account, be allowed to present dry surface during curing period
Should be the mortar per is hi.e. become dry or powdery through neglect of watering.
The relevant work shall be demolished and re-built by the contractor at no extra cost. It
the curing arrangement of contractor is no satisfactory the Engineer- in charge may
engage a casual labourer equipment for curing and recover his expenditure from
contractors.
173
E)PRELIMINARY LABORATORY TEST:
Preliminary tests on mortar cubes shall be carried out in the Projects laboratory well in
advance to adjust the exact proportions of the constituents for the best results. The
contractor shall provide the necessary material, including cement from his stocks to the
project Laboratory. The cost on account of the supply of materials for such tests will be
deemed to have been included in the item rate in the tender.
Samples of sand ,rock and mortar slurry shall be collected from the work site regularly
to check and record the v quality of the material and products going into the work. The
contractor. supply the materials for such tests and quality determination in adequate
quantities at his cost. Samples of sand and rubble shall be collected at least for every500
cubic meters of Colgrout Masonry or once in a week whichever is earlier. Samples of
rubbles be collected at least once in three months.
The results of the test will indicate the quality of the material and products going into the
work .The contractor shall take due note of any substandard quality of low strengths that
will be revealed by the test and will improve the quality of material, processing and
workmanship to produce a better quality of colgrout Masonry.
F) WORKTESTOFCOLGROUTMORTARSLURRY
For work tests samples shall e taken on the job for every 100cubic meters of Colgrout
Masonry and at least three times a day .At the time of each sampling, there test samples
shall be filled. These samples shall be collected from n earth replacement location of the
colgrout masonry.
G) STANDARD OF ACCEPTANCE:
All the strength tests shall be carried out as per relevant I.S.I .Specifications. The average
of the crushing strengths cubes shall be taken as the crushing strength of set providing
that the individual compressive strength of the three cubes is within15% of the average
crushing strength. Not less than 95%of the number of total acceptable sets of works tests
cubes shall indicate strengths higher than the strengths stipulate below.
Sr. No. Nominal proportion Strength stipulated

of the mortar / slurry on test cubes of 15 x
cement sand 15 x 15 cm. size at 28
days in kg/Sq.cm.
Preliminary tests Works tests
(Laboratory)
1 1:3 130 117
If the works test cube sets fail to indicate the strengths specified above, all masonry
represented by such sets of cubes of low strength shall be paid at such reduced rates as
will be decided by the Engineer- in Charge.
A review of the test cube set strengths and the corresponding mortar shall be made every
month. The volume of masonry represented by a set of work test cubes shall be considered
as 100 cubic metres.
174
The average crushing strength may be higher than the stipulated strength and contractor
shall not be entitled to any increase in specified rate on this account.
H) PROPORTION
Proportion of the ingredient to give the requisite strength shall be determined by
experiments. If the nominal mix fails to give the requisite strength, the mix shall be varied
as directed by the Engineer in charge.
WORKABILITY TEST:
The fluidity test shall consist of measuring the flow of colgrout slurry by measuring the
travel of the grout in the flow meter. For this purpose, the flow meter shall firs be wetted
and to drain for one minute and set up in perfect horizontal level. The point to which the
grout floes is read on the scale fixed n the channel which in turn indicates the fluidity of
the sample colgrout. the flow shall preferably be maintained between 40 to 50 cm. A
minimum of 3 flow meter test shall be carried out per shift per mixer. The record of such
test loading shall be maintained in a separate register.
3.19.6 ZONING OF MASONRY:

The contractor shall construct the colgrout masonry as per the zoning specified as
modified from time to time by Engineer in charge.
3.19.7 MIX VARIATIN CLAUSE FOR CEMENT:

If the proportion of cement to sand is varied, deduction shall be made for less use of
cement.
3.19.8 LAYING AND WORKMANSHIP:
3.19.9 STONES TO BE WETTED BEFORE:

All stones, chips shall be clean and free from dust or mud to ensure good bond and
adhesion with mortar slurry and shall be thoroughly moistened being laid.
For this purpose, the stones to be used immediately shall be kept sprinkled with good
clean water. There shall be good collection of stones and spauls within easy reach.
3.19.10 DRESSING OF STONES:

The stones shall be placed in the work after knocking of weak corners and edges with
masons hammer and after clearing scales of foreign matter if any.
3.19.11 LAYING:
i) Before laying the colgrout masonry it shall be ensured that the preparation of foundation
surface is completed.
175
ii) The stone shall be so placed in the compartment made cut for purpose so that the bigger
dimension is in long horizontal place. Stone chip and spauls shall be wedged into the
work wherever necessary to avoid thick beds or joints and to give necessary maximum
density.
iii)Colgrout masonry shall be constructed in blocks of different shapes and sizes so as to

avoid continuous horizontal and vertical joints. The area of each block shall be so fixed
that it can be grouted continuously in one shift of working. In any case it should not be
more than 25 to 30 square meters. The compartment walls shall be 45cm wide of UCR
masonry of same proportion as that of colgrout slurry and 0.6 to 1m in height which will
form the integral part of colgrout masonry. These walls shall be considered as a colgrout
masonry for the purpose of payment. Adequate heads shall be provided for proper
horizontal and vertical bond with colgrout masonry with surrounding layers. The
minimum number shall be one per four Sqm. area to be bounded. Then the block shall be
hand packed with rubble. The interstices shall be filled in by using small chips to reduce
voids. In top layer height stones shall be arranged for the bond with upper layer.
iv) Colgrout mortar shall be inspected under sufficient pressure by upward penetration
method in three layers f above 35cm height M.S G. I pipe of 75mm dia at 1.5 m c/c both
directions and about 25mm above the base of layers shall be used for grouting purpose.
These pipes shall be withdrawn. Simultaneously as the grouting of each layer is in
progress.
The grout shall not be brought up to the top level of stones but the about half the height of
the top stone layers so as to ensure a good bond with the next lift of colgrout masonry to
be laid.
v) CLEANING OF LAITANCE:
On filling of a block, the slurry shall be made rough, by rods, punji, wire brushes and
shrouding of metal., Before laying the next layer the laitance if any shall be removed by
jack Hammer &surface area to be cleared by air water jet, it shall be ensured all the
smooth surface area is roughened before laying next layer of masonry. No traffic shall be
allowed on the surface so prepared till the next layer is started.
VI) QUANTITY OF COLGROUT SLURRY:

Every effort shall be made to see that proper quantity of colgrout slurry is used. The
acceptable quantity of colgroutslurrywillbe40 to 43% of the masonry laid. If the
percentage of mortar slurry goes below 40% limit, subject to criteria of strength and
permeability, the rate of colgrout masonry will be reduced at the rate of Rs……………….
per cubic metre for every one percent of reduction in cement mortar slurry. If
consumption of mortar exceeds 43% by volume the same shall be at contractor's expenses
and no extra payment shall be made.
The lowest acceptable standard will be at 37% mortar slurry below which the
masonry will be dismantled and reconstructed at contractor's cost.
176
VII) A row of vertical headers shall be erected at about 2m. Centre to centre both ways
so that there is at least one vertical header for every 4 square metre in every layer
3.19.12 LIMIT ON HEIGHT OF MASONRY TO BE DONE IN A DAY:

The maximum height of masonry that will be allowed to be constructed at a time shall be
1.00m. No fresh masonry shall be laid over masonry previously laid within 24 hours of
its being laid. If sufficient working space is not available for masonry work in spite of
residual all components of the work by the contractor, this condition may be related
somewhat in exceptional circumstance by the Engineer-in-charge.
3.19.13 SCAFFOLDING TO BE DONE BY CONTRACTOR

All Steel required for the work shall be provided within the rates Quoted for the items
for masonry.
3.19.14 PROVIDING PLANK-WALK-WAYS:

Plank-walk-ways or other suitable arrangements shall be provided at the contractor’s cost
promptly for the use of necessary job-trafi cover the colgrout Masonry laid freshly and
over the Colgrout Masonry finished rough at the top surface and for inspecting and
supervision of the work. The cost ofsuchprovisionshall be deemed to be included in the
unit rate of colgrout masonry
3.19.15 DEFECTIVE WORK:

If any portion of colgrout masonry is found to be defective either in materials or in the
construction, it shall be removed and rebuilt by the Contractor without any extra cost
when so directed by the Engineer-in-charge.
3.19.16 BLOCKOUTS AND SLOTS TO BE PROVIDED BY THE

CONTRACTORS:
Block out sand slots necessary for embedding the foundation block out sand other
embedded parts shall be provided by the contractor without any extra cost
3.19.17 PREPERATION OF FOUNDATION CONCRETE OR MASONRY

SURFACE PRIOR TO LAYING
3.19.18 LAYING OF MASNORY OVER MASNORY WHICH WAS NOT

HARDENED:
A) Before laying of Colgrout Masonry, the latance on the top surface should be roughened
by panja, rods, wire brushes and shrouding of the metal. The latance if any shall be
removed by jack hammer and surface area to be cleaned with air and water jets so that
the surface is thoroughly cleaned before starting at new lift and wetted but pools of water
shall be avoided the cost of such cleaning shall be covered by the unit rate accepted for
the lens of Colgrout Masonry
177
B) The prepared and cleaned surface shall be free from traffic etc. till covered Plank-ways
shall be provided for movements. Masonry freshly laid shall not be disturbed for at least
24 hours after laying.
3.19.19 TREATMENT OF HARDENED COLGROUT MASONRY

SURFACE :
A) Masonry surfaces, which have remained exposed for more than three calendar weeks or
beyond the curing period or over which the flow of water is permitted and to which new
masonry is to be bonded shall be prepared in the same manner as preparing the original
foundation no extra payment shall be made for such treatment.
The unit rate of colgrout masonry
B) Before starting new masonry over masonry over which flow of water has been permitted
in addition to the above preparation, one layer of old masonry shall be removed and
scraped from joints in the lower layer to a depth of atleast12 mm. The layer of masonry
required to be removed shall not be paid for.
The cost of clearing and removal of masonry and scrapping of joints is covered under the
unit rate accepted lor masonry
3.19.20 TREATMENT OF HARDENED CONCRETE SURFACE:

Concrete surface, which has hardened shall be roughened by chipping to a depth of 25
mm so as to remove top mortar film and get a rough surface for starting masonry in
addition to preparation indicated for preparing the rock foundation for laying masonry.
Cost of such preparations is covered under the unit rate accepted for masonry
3.19.21 MORTAR ON THE PREPARED SURFACE:

i) Before laying colgrout masonry over the finally prepared surface of the foundation
or Theold surface of masonry or concrete the surface shall be welled for 24 hours and
then covered with a layer of cement mortar (1:2) as directed to a depth of 50mm. to
75mm. cement slurry of water cement ratio (0.6) by weight shall be applied on rock or
masonry or concrete surface before placing this mortar. The mortar shall be rubbed by
trowel to ensure good adhesion. In additionthe concrete surface shall be adequately
chiselled up and roughened before applying slurry and mortar.
ii) The cost of preparation of surface of concrete or masonry of any other material prior to
laying of masonry over it. Including the cost of the mortar of proportion as specified in
the item to be laid over the prepared surface, shall be covered in the tendered unit rate for
the item of colgrout Masonry. This shall be so, irrespective of repetitions necessary, to
ensure the desired standard of cleaning the surface.
178
3.19.22 TAKING CORES AND TESTING THEREOF:
The core of masonry of 0.9 metre diameter will be taken by Department, once during each
season or as per discretion of engineer-in-charge. Core shall be taken by drilling after
sufficient hardening of the block by using calyx shot in rotating drum of drilling machine
Contractor shall provide all facilities for taking out these cores The areas drilled shall be
back filled by Masonry or concrete as directed by the Engineer. in-charge and will be
paid under relevant item
3.19.23 PERMEABILITY:
Permeability tests shall be carried out on the constructed Colgrout masonry according to
the following procedure.
.
i) Test holes 75 mm. (or nearest commercial size) in diameter shall be drilled in two rows
at the end of each working seasons at the rate of two per 20 metercentre in
staggered manner to centre or as directed. One row in the upstream septum and the
downstream zone and to a depth extending 1.5 metre in the foundation or which over old
masonry of the previous season. The exact location of holes shall be as directed by the
Engineer-in-charge The water-in-lake shall be tested packers or in stages of 1.5 m. be
directed by the Engineer-in-charge. The test pressure shall be 1.4 kg/sq.cm. (20 psi) a top
of hole under test. The water-intake shall not be more 1.5 litre per minute per Sq. meter
peripheral surface of the hole. Length passing through concrete and foundations shall be
taken equivalent to that in masonry. If the leakage observed is within the specified limits
the holes drilled shall be grouted. The payment of drilling grouting and water intake test
deem to be included in the unit rate of colgrout masonry
ii) DRILLING AND GROUTING OF MASONRY:

If the total loss during the tests exceeds the values specified above, systematic drilling
and grouting till refusal shall be carried out by the contractor at his own cost to achieve
the required degree of permeability. In case the Contractor fails to take up the drilling and
grounting as directed the Engineer-in-charge shall do this work either departmentally or
through other contractor after issuing 10 (Ten) days notice to that effect. The cost of such
drilling and grounting as be decided by the Engineer-in-charge shall be recovered from
the contractor from the any amount due to him. The Engineer-in-charge's decision in the
smaller shall be final and binding on the contractor,
The cost of drilling of test holes, conducting permeability tests and drilling and grouting
of masonry as may be necessary shall be borne by the Contractor and shall be deemedto
have been included in the rate of masonry
iii) REMEDIAL MEASURES:

If the leakage during permeability tests exceeds the values specified above systematic
drilling and grouting shall be carried out as directed by the Engineer in charge to achieve
the required degree of impermeability. Such remedial drilling and grouting shall be
179
executed by the contractor at his cost failing which it shall be get. done by the department
at the contactors cost. Even after carrying out such remedial measures even though the
results of tests are found unsatisfactory, appropriate recovery shall be made from
the contractor for any significant leakage through the gallery and shafts or downstream
face of the dam unless the contractor carries out immediately further drilling and grouting
and such other remedial measures at his cost and corrects the defect The decision of
the Engineer-in-charge as tot extent of recovery and as to what constitute as a significant
leakage shall be final.
:
iv) RELAXATION
Notwithstanding the provision of paragraph above, the Engineer-in-charge at his
discretion may relax the permeability standards provided that the measurements
of discharge through the colgrout masonry in the gallery after the ponding on the
upstream for a sufficient period indicates satisfactory imperviousness of the Colgrout
Masonry.
..
V) PAYMENT OF PART-RATE:
A deduction of Rs per cubic metre of colgrout masonry shall be made in running account
for all colgrout masonry work of the dam section. If the permeability tests taken at the
beginning of each working seasons indicate satisfactory impermeability and or that
adequate grouting, if found necessary, has been done by the Contractor at his cost, a
refund of Hs. ) per cubic metre shall be made for such colgrout masonry quantity
which I s found to be adequately impermeable or satisfactorily grouted. The balance of
Rs) per cubic metre of colgrout masonry shall be treated as additional security deposit
and shall be retained by Corporation until such time as the lake water is raised up to crest
overflow portion to facilitate adequate observation of percolation through the dam and
the pore pressures in the body of the Dam. .
This additional security deposit shall be refunded provided the leakage through the
gallery and Thecore pressure in the body of the dam are found within acceptable limit as
decided by the Engineer.in-charge. This decision shall be takenwithin36 months of the
. leakage being raise up to crest of over flow portion.
.
3.19.24 DAMAGE DUE TO FLOODS:
CORPORATION NOT RESPONSIBLE:
Any damage to colgrout masonry due to the flood passing over the work completed in
the previous working season or caused due to floods during construction, shall be
covered by the rates quoted for the items.
No claims shall be entertained for such damages. Every season before the monsoon,
The colgrout masonry in the overflow portion (i.e., the portion over which the water will
be allowed to flow in the mansoon immediately ensuring) shall be brought to shape as
directed. No colgrout masonry work in the overflow portion may be possible during the
monsoon.
180
3.19.25 MEASUREMENT AND PAYMENT :
3.19.25.1VOLUMEFOR PAYMENT:
Payment shall be made on the net quantity of Colgrout Masonry on cubic metre basis
arrived at after deducting quantities for openings and other class of work in Dam, unless
where specifically directed otherwise, from the total volume of Colgrout Masonry. No
deductions shall be made for any openings not exceeding 150mm. in diameter or
equivalent size.
The prismoid formula will be applicable for calculating the quantities of

colgrout masonry.
3.19.25.2 RUNNING BILLS:

.In running account bills, appropriate part rate for the Colgrout masonry work will be paid
depending upon the quantities of colgrout masonry executed.
Part rate of colgrout masonry work shall be paid in the running bills on the following basis
:
When progress of masonry monolith wise as Maximum permissible ratio of part rate to the
compared with relevant monolith wise contract rate for the item.
quantities is
Upto50 percent 95 percent
Above 50 percent and 97 percent
upto90 percent 100 percent
Above 90 percent
The amounts withheld in the above manner will be in addition to the amount withheld for
permeability testing of colgrout masonry
For non-compliance with any of the provisions in the tender including specifications
for colgrout masonry work a further reduction in the rate of colgrout masonry items may
be considered by the Engineer.in-charge l or payment of the bills.
181
3.20 B.B. MASONRY (Item No. CC 35)

Providing B.B. masonry with conventional I.S type bricks for superstructure including
striking joints, watering, scaffolding with all leads and lifts including cost of material.

The work covered by this item shall consist of furnishing all materials, equipments and
labour for providing and laying brick masonry for superstructure including striking joints,
scaffolding curing etc complete.
3.20.3 MATERIAL
1. Bricks
The common burnt clay bricks shall conform to IS:1077 and shall be hand molded or
machine molded .They shall be free from modules of free lime, visible cracks, flaws
warpage and organic matter, have a frog 100mm in length 40mm in width and 10-20 mm
deep on one of its flat sides. The brick shall be modular bricks of size 200x100x100mm.
2. Cement
Only 43 grade OPC Cement shall be used for this work unless other otherwise specified
by Engineer in change. The cement shall conform to I.S 269 – 1967 and subsequent
revision of Portland cement and I.S 1489-1976 and subsequent revisions of pozollana
cement
3. Natural sand
Sand used for brickwork shall be preferably crushed sand/natural river sand with all
relevant requirement as stipulated by I.S 383-2016 and all other codes of BIS.

1. Mortar
The mortar for brick work shall be as specified and conform to accepted standards. Lime
shall not be used where reinforcement is provided in brick work.
2. Soaking of bricks –
Bricks shall be soaked in water before use for a period for the water to just penetrate the
whole depth of bricks, When bricks and soaked they shall be removed from the tank
sufficiently early so that at the time of laying they are skin dry.
3. Laying -
Bricks shall be laid in English Bond unless otherwise specified. Half or cut bricks shall
not be used except as closer where necessary to complete the bond.
The walls shall be taken up truly in plumb or true to required batter where specified. All
courses shall be laid truly horizontal and all vertical joints shall be truly vertical. Vertical
joints in the alternate course shall come directly one over the other. Quoins, Jambs and
other angles shall be properly plumbed as the work proceeds. The brick work shall be
built in uniform layers. The joints shall be squared raked out to a depth of 1cm while the
mortar is steel green.
182
4. Curing–
The brick work shall be constantly kept moist on all shall faces for a minimum period of
seven days.

Brickwork shall be measured in cubic meters. No deduction shall be done for opening up
to 0.10 sq.m.

Payment shall be made on one cubic meter basis.
183
3.21 B. B MASONRY WITH CONVENTIONAL I.S TYPE BRICKS IN
CEMENT MORTAR (Item No. CC 36)

Providing B. B masonry with conventional I.S type bricks in cement mortar 1:5 in
superstructure up to floor level including mild steel reinforcement of 2 bars 6mm dia.
placed by every 3rd course properly bent , bounded at ends, scaffolding watering etc.
complete with all leads and lifts including cost of material .

The work covered by this item shall consist of furnishing all materials equipments and
labour for providing and laying half brick masonry for superstructure.
3.21.3 MATERIAL
1.Bricks-
The common burnt clay bricks shall conform to IS:1077 and shall be hand molded or
machine molded. They shall be free from modules of free lime, visible cracks, flaws
warpage and organic matter, have a frog 100mm in length 40mm ln width and 10-20 mm
deep on one of its flat sides. The brick shall be of modular bricks of size 200x100x100mm
.
2.Cement
Only 43 grade OPC cement shall be used for this work unless otherwise specified by
Engineer in change. The cement shall conform to I.S 269 – 1967 and subsequent revision
of Portland cement and I.S 1489-1976 and subsequent revisions of pozollana cement.
3.Natural sand – sand used for brickwork shall be preferably crushed sand/natural river sand
with all relevant requirement as stipulated by is 383-2016 and all other codes of BIS.
3.21.4 SEQUENCE OF EXECUTION.
1. Mortar :-
The mortar for brick work shall be as specified and confirm to accepted standards. Lime
shall not be used where reinforcement is provided in brick work.
2. Soaking of bricks –
Bricks shall be soaked in water before use for a period for the water to just penetrate the
whole depth of bricks, When bricks and soaked they shall be removed from the tank
sufficiently early so that at the time of laying they are skin dry.
3.Laying : For brickwork in half brick wall, bricks shall be laid in stretcher bond.
After every 3rdcourse a band shall be laid with steel reinforcement as mentioned in the
item.
4. CURING–
The Brick work shall be constantly kept moist on all faces for a minimum period of seven
days.
Walls half brick and less shall each be measured separately in square meters stating
thickness.
3.21.6 MODE OF PAYMENT –

Payment shall be made on one square meter basis.
184
3.22 (Item No. 37A to Item No. 38A).

Providing and supplying cement concrete pipes, conforming to IS 458-2003 of NP2, NP-
3 and P1 class and various diameter including cost of all material and labour required,
inspection charges, transportation to stores, transit insurance, loading, unloading and
stacking excluding GST levied by GOI and GOM in all respect etc. complete.

This Specification covers the requirements of Providing and supplying cement concrete
pipes, conforming to IS 458-2003 of following class and diameter including cost of all
material and labour required, inspection charges, transportation to stores, transit
insurance, loading, unloading and stacking.

3.22.3.1 Introduction
Concrete pipes shall be of the class and diameter mentioned in the item and shall comply
with I.S. 458-2003 and brought by the contractor near the site of work.
The collars shall be of the appropriate size for fixing of the concrete pipes specified on
drawings and shall comply with the I.S. 458-2003
The cement mortar shall comply with specifications stipulated in section - 9. The
Contractor shall provide on-site training on RCC pipe laying, jointing, testing and
maintenance etc., to the personnel authorized by Engineer-in-Charge.
3.22.3.2 Applicable IS Codes

The manufacturing, testing, supplying, laying, jointing and testing at work sites of RCC
pipes shall comply with all currently applicable statutes, regulations, standards and
Codes. In particular, the following standards, unless otherwise specified herein, shall be
referred. In all cases the latest revision of the Codes shall be referred to. If requirements
of this Specification conflict with the requirements of the standards/Codes, this
Specification shall govern.
IS: 458 Precast Concrete Pipes (with and without

Reinforcement)
3.22.3.3 Raw Materials

Raw materials used to manufacture RCC Pipes are cement, aggregates, water, admixture,
steel reinforcement.
(i) Cement
The cement used in the manufacture of RCC pipes shall conform to one of the following.
1) Cement used for manufacturing shall confirm to I.S. 269 – 1976 (OPC) or latest.
2) 43/53 grade Ordinary Portland Cement conforming to IS:8112/IS 12269
3) Rapid Hardening Portland cement conforming to IS: 8041
4) Portland Slag cement (with not more than 50% slag) conforming to IS: 455
5) Sulphate resisting Portland Cement conforming to IS: 12330
185
ii) Aggregate
The coarse and fine aggregates shall conform to I.S.383. The maximum size of aggregate
shall not exceed one third the thickness of the pipe or 20mm whichever is smaller. Silt
Content in fine aggregates shall be less than 3 percent. The fineness modulus of
aggregates for coating shall be between 2.6 to 3.2.
iii)Water
The water used in the preparation of concrete mix shall be clean and free from harmful
or injurious compounds such as acids, alkali, oil, organic material or other substances
and shall conform to the requirements of mixing water as per IS : 456.
iv) Admixtures
Admixtures may be used with the approval of the purchaser. However, use of any
admixture containing chlorides in any form shall be prohibited The admixtures shall
conform to IS 9103.
v) Steel reinforcement
• Prestressing steel wire shall conform to IS 1785.
• Untensioned reinforcement may consist of MS bars conforming to IS432 or HYSD
bar conforming to 1786
vi) Rubber Ring.
• Rubber gasket shall comply with I.S. 5382 – 1969 or latest. The manufacture of
pipes shall tests each gasket by stretching it to 33 1/3 % in excess of its original
length.
• Every ring shall be visually checked particularly at joint.
• Gasket shall be clearly labeled in bundle to indicate type of joints, diameter and
its tests certificate.
• The contractor shall procure adequate no of rings required for the work
irrespective of no pipes.
vii) Sampling criteria for Selection of Pipe for Testing Purpose
• All pipes for testing purposes shall be selected at random from the stock of the
manufacturer and shall be such as would not otherwise be rejected under this
standard.
viii) Pre Delivery Testing of Pipes
• The specimens of pipes selected in accordance with above para shall be subjected
to the following tests in accordance with IS 3597:
a) Hydrostatic test,
b) Three-edge bearing test. and
c) Permeability test,
• The permeability test when conducted in accordance with the method described in
IS3597shall meet the requirement of final permeability, which shall not exceed
0.3 cm'.
ix) Marking on Pipes
The following information shall be clearly marked on each pipe:
a. Indication of the source of manufacture.

b. Class and size of pipe.
186
c. The words 'SPUN PIPE' or 'VIBRATED CAST PIPE (UNREIN FORCED)' or
'VIBRATED CAST PIPE (REINFORCED)' as may be applicable, and
d. Date of manufacture. The above information shall be clearly marked on outside
only for pipes up to and including 350 mm internal diameter, and both outside and
inside for pipes above 350 mm internal diameter.
• Each pipe may also be marked with the Standard Mark.
• The use of the Standard Mark is governed by the provisions of the Bureau of Indian
Standard Act. 1986 and the Rules and Regulations made there under
• The details of conditions under which the license for the use of the Standard Mark
may be obtained from the Bureau of Indian Standards.
x) Transportation of Pipes
Following precaution shall be taken during transportation of pipes
• The vehicle shall have side supports approximately spaced 2m apart, and the pipes
shall be secured effectively during the transportation. All posts shall be flat with no
sharp edges.
• A pipe section must be rolled or otherwise moved, such operation shall be done slowly
and with every reasonable precaution against damage. Any portion of the lining,
coating that may become damaged shall be repaired with polymer Mortar.
• Pipes manufactured at factory are to be carried to the site of work directly or stacked
suitably and neatly along the alignment/ road side/elsewhere near by the work site, as
directed by the Engineer.
• All pipes shall be loaded in trucks by mechanical crane/ tripod and unloaded carefully
using crane/ tripod. No unloading using crow bars or on tires will be allowed in any
case. Rubber belt may be used instead of crow bars or chains.
• Pipes should be loaded at the works for transportation, either by rail or by road, in such
a way that they are secure and that no movement can take place on the vehicle during
transit. The same care is needed if pipes are to be transferred from one vehicle to
another, however, short the journey may be.
• Un-loading of pipes should be carried out by means of chain block with shear legs or
crane of adequate capacity, using properly designed slings and spreader beams or
specially designed lifting beams. Slings should be placed around the circumference of
the pipe and should not be threaded through the pipe bore' as the latter method may
damage the jointing surfaces. For the same reasons, hooks located in the ends of the
pipes should not be used.
Stacking Of Pipes at Site

Following precaution shall be taken while stacking of pipes so as to eliminate potential
damages to pipes.
187
• Pipes may be placed directly on the ground provided it is reasonably level and free
from rocks and other projections.
• Stacking in tiers is permissible provided timber bearers are placed between
succeeding tiers.
• Rolling down of the stacked pipes must be avoided by providing wedges wherever
required.
• All pipes shall be loaded /unloaded on/from truck by mechanical crane only. No
hook shall be used and nylon tape of sufficient size and width shall be used.
xi) Valves
For PDN work, various Valves as mentioned below are required to be provided on
pipeline at various location.
• Air Valve :
The effect of air valve in the long-distance water pipelines are in the following three
areas: firstly, in the water filled stage of the pipeline, filled with water by a certain
velocity, the air valve can discharge the remained gas in the pipe; secondly, at the
normal working stage, the air valve can discharge the small amount of gas gathered
in the pipe timely; finally, during the pump failure or maintenance stages, the air
valve will replenish the gas into the pipe to break the vacuum. According to the
orifice size, displacement and work pressure, air valve is divided into high pressure
trace exhaust valve, low pressure air release valve and combined air valve.
• Scour Valve :
These Valves are generally provided to drain out the pipeline. The exact location
of Scour valves is frequently influenced by opportunities to dispose off the water.
Where the main pipeline crosses a stream or drainage structures, there will usually
be a low point in the line but if the main pipeline goes under the stream or drain, it
cannot be completely drained into the channel. In such a situation it is better to
locate a scour connection at the lowest point that will drain by gravity and provide
for pumping out the part below the drain pipeline.
• Control Valve :
A control valve is a valve used to control fluid flow by varying the size of the flow
passage as directed by a signal from a controller. This enables the direct control
of flow rate and the consequential control of process quantities such

as pressure, temperature, and liquid level.
Common types of control valve are as given below.
A) Sliding Stem
• Globe valve
• Angle body valve
• Angle seat piston valve
B) Rotary
• Butterfly valve
• Ball valve
C) Other
• Pinch valve
• Diaphragm valve
188
xii) Post-delivery testing of pipes
After delivery of pipes to worksite, additional test, if desired by Engineer-in-charge,
shall be conducted on random samples of pipes collected from site.
xiii) Third Party Inspection

Work of PDN shall be inspected, tested and certified by PMC / TPI / QC.
Modalities of PMC / TPI / QC Inspection shall be separately decided and given
by Engineer In-charge.
Project management consultants (PMC) should have approved laboratories
certification or collaboration with N.A.B.L. (National Accreditation Board for
Testing and Calibration Laboratories)
Third party Inspection can be done form any one of the following services
or from any other mutually agreed agency.
1 Engineers India Limited, Mumbai
2 R.I.T.E.S. (Rail India Technical Economics Services)Mumbai
3 S.G.S, Mumbai
4 Visvesvaraya National Institute of Technology, Nagpur
5 VJTI, Mumbai
6 CWPRS(Central Water & Power Research Station), Pune
7 CIPET (Central Institute of Plastics Engineering & Technology)
• Testing of materials
(a) All materials before being utilized in works shall be inspected and tested, by the
Engineer In-charge or his representative/QC. The nature of testing and periodical
intervals at which such testing is to be done etc. shall be as per the latest editions
of relevant IS Codes and determined by the Engineer In-charge. The day-to-day
and periodical tests to be carried out on materials mixes and placed concrete, mortar
etc. shall be specified by the Engineer In-charge from time to time and the
Contractor shall provide free of cost all facilities towards collections of samples
etc. unless otherwise specified. Labours for collecting samples and transportation
of the samples to quality control authorities for test shall be provided free of cost
by the contractor. Also electricity, fuel, water curing tank and stores etc shall be
provided free of cost by the contractors.
(b)The materials shall be tested in QC laboratory or at any other place directed by the
Engineer In-charge. The Contractor shall obtain the test results from the concern
authority and the results given by such authorities shall be considered to determine
whether all materials, workmanship are of respective standard described in contract
and in accordance with the instructions of the Engineer In-charge. The Contractor’s
representatives shall, however, be given access to all operations and tests that may
be carried out as aforesaid so that he may satisfy himself regarding the procedure
and methods adopted. It shall then be the Contractor’s responsibility to produce on
189
the work, materials and finished item to the standard as determined by the
laboratory tests or to take follow up action to rectify the quality.
(c) Testing charges for testing of Cement, TMT bars, all types of pipes and specials
including cost of samples and its collection shall be borne by the Contractor.
(d)The Contractor shall make suitable arrangements to see that one of his
representatives remains present at the time of taking samples and shall authenticate
the facts. If the Contractor, fails to keep his representative present at site at the time
of taking samples or fail to provide required labours and other equipment to collect
the samples, the same shall be taken by the Engineer In-charge, and the samples
selected shall be considered as authentic. The cost incurred by the Engineer-In-
charge when the Contractor fails to provide required men and materials for
collecting samples and or their transport shall be recovered from the Contractor.
xiv) Quality Control and Quality assurance

• On award of contract, the Contractor will have to provide adequate quality
assurance setup including Quality Assurance Engineer backed with suitable
laboratory assistants, labours and well equipped laboratory for taking necessary
field test required as per specifications and as per instructions of Engineer in
charge.
• Following minimum persons shall be employed by the contractor at work site for
Quality Assurance.
Sr. No. Personnel with Qualification Nos.
1 Quality Assurance Engineer(Civil Engineering One

Graduate with 2 Year experience in QA testing
and report generation work)
2 Laboratory Assistants (Twelfth Pass with Two to Four

Science subject with 2 year experience in
testing of material) (As per work)
3 Laboratory Attendants Two to Four
(One for each L.A.)
190
• Following minimum equipments shall be available in the field laboratory
setup by the contractor.
Sr. No. Work Apparatus for Tests
1 Earth Work – Field density, Moisture Content, Sieves

for Sand & Metal.
Field testing Equipments
2 Concrete Work - Silt, Gradation, Moisture Content,

Slump, Cube Moulds & CTM
• It is the responsibility of the contractor to assure the desired quality of work.

Whenever the testing of construction materials, pipes are required as per the
detailed specifications or otherwise required by the Engineer-in-Charge, the same
shall be carried out at the laboratory, selected by the Engineer-in-Charge at
contractor’s cost. The other tests of mortar, concrete, sand, coarse shall be carried
out in field laboratory set up by the contractor in presence of quality control
representative at contractor’s cost. Contractor shall through this procedure assure
the quality of work.
• The materials, mixes and any other arrangements, including labours, shall be
supplied by the contractor. The samples for testing shall be taken in the presence
of Engineer-in-Charge or his representative /QC present on site. The contractor or
his authorized representative shall have a free access in these laboratories, to get
himself satisfied about procedures of testing etc. Even if the contractor or his
representative fails to remain present while collecting samples or testing, the results
will be considered as authentic and binding on the contractor.
• Contractor shall provide all test reports of material used in the work as desired from
the NABL (National Accreditation Board for Testing & Calibration Laboratories)
approved laboratories and from Quality Control, MERI laboratories of the WRD.
Contractor shall provide periodical quality assurance report
(Weekly/fortnightly/monthly) to Engineer in Charge along with proofs in support
of quality of material brought for the work, the process/ execution of work is as per
specification.
• Contractor shall submit the account of all materials brought for the work, which are
necessary for execution of work and any other data necessary to assess the quality
of work.
• If he fails to fulfill the above requirement, the required manpower for testing and
field laboratory with required equipments will be deployed by the Engineer in
charge and the charges for the same will be recovered from the contractor.
3.22.4 Sequence of Execution

• Pre delivery testing of pipes shall be carried out by the contractor in the presence
of representative of Engineer-In-charge /WRD/QC/TPI. like:
a) Hydrostatic test,
b) Three-edge bearing test. and
c) Permeability test,
191
• The permeability test when conducted in accordance with the method described in
IS3597shall meet the requirement of final permeability, which shall not exceed 0.3
cm'.
• Each pipe shall be indelibly marked in English language at either end of each pipe.
Like Manufactures name or trademark, Grade of raw material, Pressure rating,
Nominal diameter, Lot/batch No. of manufacturer, BIS certification mark, Third
Party Certification mark for each lot, Name of Department/Project for which pipes
are manufactured. Any other important matter that the manufacturer or purchaser
deems fit to be inscribed etc.
• While transporting pipes the vehicle shall have side supports approximately spaced
2m apart, and the pipes shall be secured effectively during the transportation. All
posts shall be flat with no sharp edges.
• A pipe section must be rolled or otherwise moved, such operation shall be done
slowly and with every reasonable precaution against damage. Any portion of the
lining, coating that may become damaged shall be repaired with polymer Mortar.
suitably and neatly along the alignment/ road side/elsewhere near by the work site,
as directed by the Engineer.
• All pipes shall be loaded in trucks by mechanical crane/ tripod and unloaded
carefully using crane/ tripod. No unloading using crow bars or on tires will be
allowed in any case. Rubber belt may be used instead of crow bars or chains.
• Pipes should be loaded at the works for transportation, either by rail or by road, in
such a way that they are secure and that no movement can take place on the vehicle
during transit. The same care is needed if pipes are to be transferred from one
vehicle to another, however, short the journey may be.
• Un-loading of pipes should be carried out by means of chain block with shear legs
or crane of adequate capacity, using properly designed slings and spreader beams
or specially designed lifting beams. Slings should be placed around the
circumference of the pipe and should not be threaded through the pipe bore' as the
latter method may damage the jointing surfaces. For the same reasons, hooks
located in the ends of the pipes should not be used.
succeeding tiers.
required.
• All materials before being utilized in works shall be inspected and tested, by the
Engineer In-charge or his representative/QC.
• After delivery of pipes to worksite, additional test, if desired by Engineer-in-
charge, shall be conducted on random samples of pipes collected from site.
• For the desired quality of work. Whenever the testing of construction materials,
pipes are required as per the detailed specifications or otherwise required by the
Engineer-in-Charge, the same shall be carried out at the laboratory, selected by the
Engineer-in-Charge at Contractor’s cost.
192
• The net length of pipes as laid or fixed shall be measured in running meters correct to
a cm. Specials shall be excluded and measured in running meters or numbers as
specified by Engineer-in-charge and paid for separately under the relevant item. The
portion of the pipe overlapped at the joints shall not be included in the length of pipe
work. Excavation, refilling, anchor blocks, thrust blocks wherever required shall be
measured and paid for separately under relevant items of work.
• Damages during transit, handling, storage will be to the Contractor’s account and
replacement for such pipes has to be made by the Contractor without any extra cost as
directed by the Engineer-in-Charge

• Payment
The break up to payment for supplying, laying, jointing & hydrostatic testing of
pipeline shall be as under:-
A) 80% of the payment will be released after supplying, lowering, laying, jointing
and third party inspection of pipes in one WUA area.
B) Balance 10% of the payment will be released after satisfactory hydraulic testing
of pipeline and backfilling of trenches.
C) Remaining 10% amount will be withheld and it will be released after successful
maintenance and operation for a period of five years after commissioning of
work of respective WUAs.
The schedule of release of this 10% will be in following manner,
1) After Successful Operation and Maintenance for First year-2%

2) After Successful Operation and Maintenance for Second year-2%
3) After Successful Operation and Maintenance for Third year-2%
4) After Successful Operation and Maintenance for Fourth year-2%
5) After Successful Operation and Maintenance for Fifth year-2%
193
3.23.1 Description of Item (Item No. CC 37B, CC 38B , CC 39)
Lowering, laying and jointing in proper grade and alignment R.C.C. pipes with collar
joints in C.M.1:1 proportion or socketed R.C.C. pipes with rubber joints (excluding cost
of rubber ring or R.C.C. collar,) including cost of conveyance from stores to site of work,
cost of jointing material, labour, etc. complete as directed by Engineer-in- charge (For all
class of pipes.) as per IS- 783-1985.
3.23.2 Scope of work.

This specification covers the requirements for successfully, lowering, laying, jointing and
testing in proper grade and alignment R.C.C. pipes with collar joints in C.M.1:1
proportion or socketed R.C.C. pipes with rubber joints (excluding cost of rubber ring or
R.C.C. collar,) including cost of conveyance from stores to site of work, cost of jointing
material, labour, etc. complete as directed by Engineer-in- charge (For all class of pipes.)
as per IS- 783-1985.
3.23.3 Site Preparation

• Clearing the Site
The Contractor shall clear the entire area required for setting out. All tree stumps,
roots, brushwood, rubbish of all kinds, loose stones and all other objectionable
materials shall be removed by the Contractor. Buried irrigation pipeline, and other
structure, if any, shall be removed by the Contractor. The ownership of all the usable
material, so removed from clearing site and/or excavation shall rest with the Engineer
In-charge. Useful material shall be stacked as directed. The Contractor shall dispose
off all unuseful materials as directed by the Engineer In-charge.
• Demarcation
All materials such as pegs, bamboo’s and strings and templets for marking out slopes,
and labour required for line out should be provided by the Contractor at his own cost.
The center line of excavation shall be clearly marked by pegs or by stones at each
chain or change of direction or at shorter intervals on curves, in the beginning. The
final line out will be done by fixing reference stone at suitable distances on either side
of the center line, beyond the canal edges so that they are not disturbed during the
construction period. The position of these stones will be marked on the cross section.
• Contractor shall provide and maintain the quarry roads and temporary roads required
forconstruction activity at his own cost.
• Fixing Permanent Benchmark

(a)Benchmarks fixed by the Survey of India and temporary benchmarks established by
the Engineer In-charge in vicinity of PDN work will serve as control points for these
works. The Contractor shall establish sufficient number of reference benchmarks for
facilitating setting out of work and taking levels for the purpose of measurements.
(b)Before starting any work, the Contractor shall erect reference benchmarks, reference
lines and check profiles at convenient locations approved by the Engineer In-Charge.
194
The benchmark concrete block shall be 200mm x200mm x600mm with 400mm
embedded in the firm ground and 200 mm projecting above ground. The word ‘BM’
showing value of R.L. in ‘m’ shall be conspicuously carved and painted on the
benchmark.
(c) The check profile shall be located 30m apart or closer as directed by the Engineer In-
Charge so as to ensure execution of all slopes, steps and elevations to the profile or
profiles indicated in the approved drawings. All important levels and all control points
with respect to benchmarks and reference lines shall be fixed and correlated by the
Contractor. The Contractor is fully responsible for maintaining all setting out work &
Benchmark established by Engineer-In-charge.
(d)All materials, labour and equipments (theodolites, levels, distometre, etc.) for setting
out works including construction of benchmarks in concrete, reference lines, check
profiles and surveys as may be required at the various stages of construction shall be
supplied by the Contractor a this cost. For this following numbers of minimum
equipments shall be provided and maintained in good working condition by the
Contractor.
1. Total station and its accessories 1 set
2. Theodolite (Accuracy1second) 1No.
3. Levels 2Nos.
4. Staves 4Nos.
5. Tapes, chains ,rangingrods etc. As required
All equipment shall be of standard and approved make and precision, and shall be made
available in advance of starting of the work. All equipment shall be maintained, repaired
and got tested and certified as and when required for its accuracy from the standard test
houses or from the manufactures and to the satisfaction of the Engineer-In-Charge.
• Excavation for Pipe Trenches

• Excavation of pipe trenches shall be carried out as per excavation line shown in
the drawing or as directed by Engineer In -charge. Contractor must assume all
responsibility for deductions and conclusion made by him as to the nature of the
materials to be excavated and the difficulties of making and maintaining the
required excavation. The trench width at bottom shall be 300 mm more than 1.5
times outside pipe diameter. In any case trench width shall not be less than 500
mm.
195
• The usable excavated material available from the excavated trenches (PDN) shall
be used in backfilling. If such usable material is in excess of the requirement of
backfilling, the same shall be deposited in the spoils as and where directed by the
Engineer In-charge. Unuseful material from excavation shall be deposited in
spoils as and where directed by Engineer-In-charge.
• Surface or sub-soil water met with during trench excavation (PDN) and structure
excavation shall be diverted to nearby drain/nalla by cutting an open channel
from trench. When the drain/nalla bed is higher than the sub-soil water level met
with, the bailing out by suitable means of pumping shall be resorted to for
dewatering sub-soil water below the drain/nalla bed level. No distinction shall be
made as to whether the material being excavated is dry, moist, wet or slushy. The
Contractor shall have to excavate the PDN pipe trench and structure in under
water level conditions also i.e. under wet/slushy condition after providing
sufficient arrangement of dewatering. The material excavated under water level
condition which requires intermediate stacking for drying shall have to be
rehandled. No extra payment for efforts for drying out of soil, re-handling of dry
soil, etc. shall be given. No payment for extra efforts for excavation under this
condition shall be made.
• Over excavation performed by the Contractor for any purpose or reason, except
for additional excavation as may be directed by the Engineer-In-charge, shall be
rectified at the cost of the Contractor. Filling and compaction for such over
excavation using the material as directed by the Engineer In- Charge shall also
be at the cost of the Contractor.
• In the PDN and structure section where expansive type of the soil such as CH
type of soil is encountered and over which PDN cannot be directly laid, the PDN
trench and structure shall be over excavated to the extent as directed by the
Engineer In Charge and such over excavated section shall be filled with
suitable murum type soil to be placed in uniformly compacted layers as directed
by the Engineer In Charge. The over excavation made in such strata, filling by
suitable soil, and watering and compacting such soil will be paid separately
under relevant items. Above provision for over excavating and filling with
suitable murum type or good soil available material shall be applicable in case
such treatment is found essential.
• Laying of Pipes
• While laying of RCC pipe, all precaution as mentioned in IS 783 shall be taken.
Concrete pipes have to be properly handled, bedded & back filled, if they have
to carry the full design loads safely.
• Pipes should be lowered into the trench with tackle suitable for the weight of
pipes, such as well-designed shear slings with chain block or mobile crane.
• While lifting, the position of the sling should be checked when the pipe is just
clear off the ground to ensure proper balance.
• Laying of pipes shall preferably proceed upgrade of a slope.
• When laying is not in progress, the open end of the pipe line should be fitted with
temporary end-closure. This may make the pipe buoyant in the event of the trench
becoming flooded and any movement of the pipes should be prevented either by
partial refilling of the trench or by temporary strutting.
• When gradient for pipe laying is steeper than 1 in 6, suitable transverse anchor
blocks as specified in IS 783 shall be provided for anchoring of pipeline.
196
• Expansion joints shall be provided for buried lines at maximum interval of 100m,
if rigid joints are used.
• Each pipe shall be thoroughly checked for any damages before laying and only
the pipes which are approved by the Engineer shall be laid.
• Bedding requirements are minimal due to rigid nature of pipe. However, while
laying in rocky area, 150 mm compacted fine sand bedding under and around
pipe needs to be provided.
• The trench shall be kept free of water till the jointing has been properly done.
• After laying, if any pipe for fitting is found faulty, the contractor shall have to
replace the same at his own cost. Pipes shall be laid true to line and grade, as
specified. The lowering shall done by a tripod and chain pulley block.
• Laying of pipes shall always proceed upgrade of a slope. If the pipes have spigot
and socket joints, the socket ends shall face up stream. Adequate and proper
expansion joints shall be provide if so specified by a separate item in the order
items.
• In places where the natural foundation is in inadequate the pies shall be laid over
in a concrete cradle supported on proper foundations or on any other suitable
designed structure as per details given by the engineer-in-charge. Concrete cradle
bedding is used, the depth of concrete cradle bedding used, the depth of concrete
below the bottom, the pipes subject to a minimum of 10 cm. And maximum of
30 cm. To a distance of ¼ of the outside diameter for pipe 30 cm. and over in dia.
the pipe shall be laid in this concrete bedding before the concrete has set. The
exact details of cradle shall be as directed by the engineer in charge.
• When the pipe is laid in a trench in rock, shale or other hard material the space
below the pipes shall be excavated and released with an equalize bed of metal
sand or compacted murum. In no case shall the pipe be laid directly on such hard
material.
• The bedding viz. of murum, sand or metal shall be done if ordered by the
Engineer to the required grade and alignment to the checked by sight trials and
boning rods as directed by the Department Bedding will be separately paid for
unless specifically included in other items.
• Jointing of Pipes
:
• Spun yarn and hemp dipped in hot bitumen shall be inserted inside the groove
gap between two adjacent pipes and the next pipe pressed home with jack.
• The R.C.C. collar of appropriate dia. which is inserted earlier on the pipe shall
then be placed at the junction and cement mortar of 1:1 prop (Cement and sand)
shall then be caulked inside the clearance between the pipe and collar using angle
iron ring for support against the collar.
• The sand to be used for jointing shall be entirely free of clay and other foreign
materials. The neat cement and sand to be used for jointing shall be mixed with
just little quantity of water to make the mixture moist so that when the mixture
is gripped tightly in hand, it shall just retain its shape and not fall down nor leave
any trace of moist cement on hand.
• The angle iron ring shall be removed after the caulking is completed and neat
filled joints of cement mortar 1:1 shall be made on both sides of the collar giving
a neat finish.
• Joints may be of the following types depending on the type of pipes supplied.
Collar joints with cement mortar and rubber ring joints.
197
• In all pipe lines, in case of coller joints the recess at the end of the pipe shall be
filled with jute bedding or hemp of ambadi dipped in hot bitumen or other
suitable approved compound. The bitumen ring shall be thoroughly compressed
by jacking or other method.
• The no. of pipes to be jacked at a time shall be decided by the Engineer in charge
to ensure sufficient compression no, effect at joint shall be seen.
• Loose coller be set up over the joint so as to have even caulked space all around
and into this caulking space shall be rammed (1:1) mixer of cement and sand just
sufficiently moistened to held together in the form of clod when compressed din
the hand. The caulking shall be done using angle iron ring for support against the
coller.
• Sand used shall be well graded with maximum particles size limited 3/16 inch or
5 mm. in case of wall types of C.M. type of C.M. joints.
• CURING OF JOINTS :
• Every joints shall be kept wet for ten days. The joints shall be covered with gunny
bags so as to have proper curing and kept continuously wet.
• Every joints shall be kept wet for above ten days for maturing. The section of the
pipe lines laid and jointed shall be covered immediately to protect it from weather
effects. A minimum layer of 10 cm. is considered adequate. The joints may be
left exposed for observation.
• BELL MOUTH ENTRY :

• The shape of the bell mouth shall be as shown in the drawing. The bell mouth
shall be constructed in cement concrete 1:2:4 prop, and pipe shall end at distance
of 1/2 dia of the vertical face of upstream at entry. This shall be done with semi
mould steel template. Finished shape and texture shall be good. Upper half cast
like arch and usual precautions in casting shall be observed.
• Backfilling of Pipe Trenches

(a) The type of material used for backfilling and the manner of depositing the
material, shall be subject to approval by the Engineer-in-Charge.
(b) The backfill material shall be placed to the line and grades as shown on
drawings or as prescribed in this paragraph or as directed by the Engineer-
in-Charge.
(c) The backfill material shall be placed carefully and spread in uniform layers
of not more than 15cm thickness, with the first layer watered and
compacted by stamping or by mechanical means. The backfill shall be
brought up as uniformly as practicable on both sides of pipe to prevent
unequal loading.
(d) Only soft earth and gravel of good quality free from boulder, roots,
vegetable matters etc. shall be used for refilling of trench up to 300mm
above the top of the pipe. If sufficient quantity of suitable (Sharp edge stone
free) excavated earth is not available, the trench shall be filled by borrowed
gravel material up to 300 mm above top of pipeline. Remaining trench can
be filled with available material.
(e) When compacting the soil against steep rock, abutment walls of concrete
structures, rollers shall not be used close to structures as structural damage
is very likely more particularly when structures have not been fully cured.
The size and weight of equipment will depend on nature of material, the
198
height and load assumed in design of structure. The backfill close to the
structure up to the rolled layer shall be compacted in suitable uniform
layers, using pneumatic / hand tampers as appropriate for dry density at
average bulk density (+/- 10%). The moisture content of the earth fill
placed against the rock or the structure shall be on higher/lower side of
OMC by about 2% or so, to allow it to be compacted. Profuse watering
shall be done to pervious materials (sand) before compaction as per
instruction of the Engineer-in-Charge. Compaction at junction of
earthwork and backfill around the structure shall be carried out with special
care.
(f) The trench shall be refilled so as to built-up the original ground level.
• Permanent markings of Pipe alignment

• The contractor shall establish the sufficient number of reference blocks on the
alignment of PDN preferably at the interval of 30m or as suitable on the field
boundaries so as they will not be disturbed during the agricultural activities of
the farmers.
• The marking shall be constructed in prefabricated concrete block of size
(15x15x45)CM embedded in concrete block of size (30x30x30)CM. The base
of this block shall be buried in ground projecting only 15cm above the ground
and the base concrete block.
• These blocks shall be able to locate the pipeline as and where it is laid all over
the work. The contractor shall mark each block with specific distinct
identification mark.
• The contractor shall show all this blocks jointly to the Engineer-in-charge or his
representative, representative of WUA, concern farmers sharing the boundaries,
TPI, any other stake holders in the command.
• Contractor shall maintained these blocks in proper order during operation
&maintenance period of the contract. Any damage done to these blocks for the
reasons whatsoever shall be made good at the cost of contractor.
• The contractor shall submit the location of such blocks with specific
identification marks with schedule on a special command area map.
• The map of marking of the block shall be handed over to WUA while handing
over the command area.
• The Geotagging map showing Latitude and Longitude Value of each apex of
laid pipeline shall be submitted to Department and WUA for future reference.
• The contract shall fix information boards of 1.2 m x 0.9 m size at various location
as directed by Engineer-in-charge. On this boards, salient features of the work (eg.
Pipe diameter, pipe type, discharge, any other specific details suggested by
Engineer-In-Charge) shall be written.
• Third Party Inspection

• Work of PDN shall be inspected, tested and certified by PMC / TPI / QC.
199
3 S.G.S, Mumbai
4 Vishveshvaraya National Institute of Technology, Nagpur
5 VJTI, Mumbai
Engineer In-charge or his representative/QC. The nature of testing and
periodical intervals at which such testing is to be done etc. shall be as per the
latest editions of relevant IS Codes and determined by the Engineer In-charge.
The day-to-day and periodical tests to be carried out on materials mixes and
placed concrete, mortar etc. shall be specified by the Engineer In-charge from
time to time and the Contractor shall provide free of cost all facilities towards
collections of samples etc. unless otherwise specified. Labours for collecting
samples and transportation of the samples to quality control authorities for test
shall be provided free of cost by the contractor. Also electricity, fuel, water
curing tank and stores etc shall be provided free of cost by the contractors.
(b)The materials shall be tested in QC laboratory or at any other place directed by
the Engineer In-charge. The Contractor shall obtain the test results from the
concern authority and the results given by such authorities shall be considered
to determine whether all materials, workmanship are of respective standard
described in contract and in accordance with the instructions of the Engineer In-
charge. The Contractor’s representatives shall, however, be given access to all
operations and tests that may be carried out as aforesaid so that he may satisfy
himself regarding the procedure and methods adopted. It shall then be the
Contractor’s responsibility to produce on the work, materials and finished item
to the standard as determined by the laboratory tests or to take follow up action
to rectify the quality.
(d)The Contractor shall make suitable arrangements to see that one of his
representatives remains present at the time of taking samples and shall
authenticate the facts. If the Contractor, fails to keep his representative present
at site at the time of taking samples or fail to provide required labours and other
equipment to collect the samples, the same shall be taken by the Engineer In-
charge, and the samples selected shall be considered as authentic. The cost
incurred by the Engineer-In-charge when the Contractor fails to provide
required men and materials for collecting samples and or their transport shall
be recovered from the Contractor.
200
• Quality Control and Quality assurance
field test required as per specifications and as per instructions of Engineer in charge.
Quality Assurance.

2 Laboratory Assistants(Twelth Pass with Two to Four

(One for each L.A.)


for Sand & Metal.

• It is the responsibility of the contractor to assure the desired quality of work. Whenever
the testing of construction materials, pipes are required as per the detailed
specifications or otherwise required by the Engineer-in-Charge, the same shall be
carried out at the laboratory, selected by the Engineer-in-Charge at contractor’s cost.
The other tests of mortar, concrete, sand, coarse shall be carried out in field laboratory
set up by the contractor in presence of quality control representative at contractor’s
cost. Contractor shall through this procedure assure the quality of work.
• The materials, mixes and any other arrangements, including labours, shall be supplied
by the contractor. The samples for testing shall be taken in the presence of Engineer-
in-Charge or his representative /QC present on site. The contractor or his authorized
representative shall have a free access in these laboratories, to get himself satisfied
about procedures of testing etc. Even if the contractor or his representative fails to
201
remain present while collecting samples or testing, the results will be considered as
authentic and binding on the contractor.
• Contractor shall provide all test reports of material used in the work as desired from the
NABL (National Accreditation Board for Testing & Calibration Laboratories)
(Weekly/fortnightly/monthly) to Engineer in Charge along with proofs in support of
quality of material brought for the work, the process/ execution of work is as per
specification.
necessary for execution of work and any other data necessary to assess the quality of
work.
• If he fails to fulfill the above requirement, the required manpower for testing and field
laboratory with required equipments will be deployed by the Engineer in charge and
the charges for the same will be recovered from the contractor.

• The Contractor shall clear the entire area required for setting out. All tree stumps,
materials shall be removed by the Contractor.
• All materials such as pegs, bamboos and strings and templets for marking out
slopes, and labour required for lineout should be provided by the Contractor at his
own cost.
• The center line of excavation shall be clearly marked by pegs or by stones at each
final lineout will be done by fixing references to neat suitable distances on either
side of the center line, beyond the canal edges so that they are not disturbed during
the construction period.
• Prior permission of other department like P.W.D., H.P.C.L, M.J.P. shall be taken
if the alignment of pipe line crosses railway line, roads, gas pipe lines etc.
• Benchmarks fixed by the Survey of India and temporary benchmarks established
by the Engineer In-charge in vicinity of PDN work will serve as control points.
• Before starting any work, the Contractor shall erect reference benchmarks,
reference lines and check profiles at convenient locations approved by the
Engineer In-Charge.
• All materials, labour and equipments (theodolites, levels, distometre, etc.) for
setting out works including construction of benchmarks in concrete, reference
lines, check profiles and surveys as may be required at the various stages of
construction shall be supplied by the Contractor at his cost.
the drawing or as directed by Engineer In-charge.
be used in back filling. If such usable material is in excess of the requirement of
Engineer In-charge.
• In the PDN and structure section where expansive type of the soil such as CH type
of soil is encountered and over which PDN cannot be directly laid, the PDN trench
and structure shall be over excavated to the extent as directed by the Engineer In-
Charge and such over excavated section shall be filled with suitable murum type
soil to be placed in uniformly compacted layers as directed by the Engineer In-
202
Charge. The over excavation made in such strata, filling by suitable soil, and
watering and compacting such soil will be paid separately under relevant items.
Above provision for over excavating and filling with suitable murum type or good
soil available material shall be applicable in case such treatment is found essential.
• Before the pipes are lowered and laid in position the contractor shall see that the
invert at the support is correct and pipe is brought to uniform grade and level. This
should be checked with the help of dumpy level and should be got approved in
advance from Engineer-in-charge.
• While laying of RCC pipe, all precaution as mentioned in IS 783 shall be taken
• Valve like Air valve, Scour Valve and Control valve shall be constructed as per
drawings.
• . Concrete pipes have to be properly handled, bedded & back filled, if they have to
carry the full design loads safely.
• Pipes should be lowered into the trench with tackle suitable for the weight of pipes,
such as well-designed shear slings with chain block or mobile crane.
• While lifting, the position of the sling should be checked when the pipe is just clear
off the ground to ensure proper balance.
• Expansion joints shall be provided for buried lines at maximum interval of 100m,
if rigid joints are used.
• Each pipe shall be thoroughly checked for any damages before laying and only the
pipes which are approved by the Engineer shall be laid.
laying in rocky area, 150 mm compacted fine sand bedding under and around pipe
needs to be provided.
• Jointing of pipes shall be done as per procedure mentioned in IS 783. The sections
of the pipe should be jointed together in such a manner that there shall be as little
unevenness as possible along the inside of the pipe. As soon as joint assembly is
complete, the last pipe laid should be firmly restrained in position until backfilling
over it is complete and well compacted.
• The backfill material shall be placed carefully and spread in uniform layers of not
more than 15cm thickness, with the first layer watered and compacted by stamping
or by mechanical means. The backfill shall be brought up as uniformly as
practicable on both sides of pipe to prevent unequal loading.
• Only soft earth and gravel of good quality free from boulder, roots, vegetable
matters etc. shall be used for refilling trench up to 300mm above top of pipe. If
sufficient quantity of suitable (Sharp edge stone free) excavated earth is not
available, the trench shall be filled by borrowed gravel material up to 300 mm
above top of pipeline. Remaining trench can be filled with available material.
• Pipe embedment backfill shall be stone-free excavated material.
• The trench shall be refilled so as to built-up the original ground level
• The moisture content of the earth fill placed against the rock or the structure shall
be on higher/lower side of OMC by about 2% or so, to allow it to be compacted.
203
Profuse watering shall be done to pervious materials (sand) before compaction as
per instruction of the Engineer-in-Charge.
• Compaction at junction of earthwork and backfill around the structure shall be
carried out with special care.
• The contractor shall establish the sufficient number of reference blocks for
permanent marking on the alignment of PDN preferably at the interval of 30m or
as suitable on the field boundaries so as they will not be disturbed during the
agricultural activities of the farmers.

• Measurement
The net length of lowering, laying & jointing of pipes as laid or fixed shall be measured
in running meters correct to a cm. The portion of the pipe overlapped at the joints shall
not be included in the length of pipe work. Excavation, refilling, anchor blocks, thrust
blocks wherever required shall be measured and paid for separately under relevant
items of work.
• The measurement shall be for the length of pipes provided and fixed with collars/
Rubber ring up to bell mouth, limiting the length to that specified in the plan, or as
ordered by the Engineer-in-charge. The length shall be measured correct to a
centimeter.
• Joints to be used are rubber ring joints unless specifically mentioned otherwise in
wording of item, the rate of lowering, laying and jointing shall include cost of jointing
material such as rubber ring etc. and labour etc.

• Payment
pipeline shall be as under: -
A) 80% of the payment will be released after supplying, lowering, laying, jointing and
third-party inspection of pipes in one WUA area.
B) Balance 10% of the payment will be released after satisfactory hydraulic testing of
pipeline and backfilling of trenches.
maintenance and operation for a period of five years after commissioning of work of
respective WUAs.
204
3.24 CONCRETE OF GRADE M-20 FOR STAUNCH WALL. (Item no CC
40)
Providing and laying in-situ cement concrete of grade M-20 of trap /granite /gneiss
/quartzite /graded metal for staunch wall with batching plant and transit mixer including
shuttering, scaffolding, placing, compacting, curing etc. complete with all leads and lifts.

labour for providing and laying in-situ cement concrete for staunch wall for R.C.C pipe
joints, curing and performing all the functions necessary and ancillary thereto.
3.24.3MATERIALS:
The specifications of cement concrete section shall apply for this item.

1. The work of concrete for staunch wall shall be carried after the pipes are laid true to
line and grade and jointing of pipes is completed as specified in the specification of
relevant items. The specification of cement concrete section shall apply for concrete
in this item.
2. Curing-
Every staunch wall shall be kept wet for ten days. The staunch wall shall be covered with
gunny bags so as to have proper curing and kept continuously wet.
3.24.5MODE OF MEASUREMENT
Payment shall be on the net quantity of concrete after deducting quantity of R.C.C
pipes.
Payment at the rate of 1% shall be withheld in running payment.

The unit for payment shall be one cubic metre.
205
3.25 PROVIDING AND FIXING R.C.C BOUNDARY/ GUARD/
CHAINAGE BLOCKS (item no CC 41)
Providing and fixing R.C.C Boundary / Guard / Chainage blocks of size 75x20x20 cm
including excavation and fixing in a block of 45 x 45 x 45 in M- 15 concrete with oil
painting of two coats, lettering etc. complete, height of stone above GL 40 cm.

The work covered by this item shall consist of furnishing all materials, equipment and
labour for providing and fixing RCC Boundary / Guard / Chainage blocks including
excavation, concrete, painting and lettering as directed by Engineer in charge and
mentioned in item above.
3.25.3 MATERIALS:
The specification for materials required for concrete blocks and concrete shall be same
as described in specification of concrete work. The compressive strength of concrete
blocks shall be as per strength of concrete grade M20 as specified in the specification of
concrete. Steel reinforcement of 10mm dia.4 no. vertical and 6mm dia. rings at 150mm
c/c shall be embedded in concrete block. The size of concrete block shall be as mentioned
in the item above.

1. Fixing: The concrete shall be embedded in concrete for M15 grade and shall confirm
to the specifications given under section of concrete.
Any excavation necessary for fixing of concrete block and laying of cement concrete
bedding is included in the rate and shall be done by the contractor at his cost.
2. Curing for concrete shall be done for at least seven days and shall be covered with
gunny bags as to have proper curing and kept continuously wet.
3. Exposed part of the block shall be given two coats of oil paintings, lettering as per the
directions of Engineer in charge.
3.25.5 MODE OF MEASUREMENT AND PAYMENT.

The contractor shall be paid for one Boundary /Guard/ Chainage block inclusive of
excavation, concrete oil painting and lettering.
206
3.26 PROVIDING AND FIXING R.C.C KM/HALF KM/SUBMERGENCE
BOUNDARY BLOCKS. (Item no. CC 42)

Providing and fixing R.C.C Km/Half km/submergence boundary blocks of size
95x20x20cm including excavation and fixing in a block of 45x45x45cm in M-15 concrete
with oil painting two coats lettering etc. complete, height of stone above GL 60cm.

labour for providing and fixing RCC Km/half km/ submergence boundary blocks
including excavation, concrete and painting, lettering as directed by Engineer in charge
and mentioned in the item above.
3.26.3 MATERIALS:
The specification for materials required for concrete blocks and concrete shall be same
as described in specification of concrete work. The compressive strength of concrete
blocks shall be as per strength of concrete grade M20 as specified in the specification of
concrete. Steel reinforcement of 10mm dia.4 no. vertical and 6mm dia. rings at 150mm
c/c shall be embedded in concrete block. The size of concrete block shall be as mentioned
in the item above.

1. Fixing: The concrete shall be embedded in concrete for M15 grade and shall confirm
to the specifications given under section of concrete.
Any excavation necessary for fixing of concrete block and laying of cement concrete
bedding is included in the rate and shall be done by the contractor at his cost.
2. Curing for concrete shall be done for at least seven days and shall be covered with
gunny bags as to have proper curing and kept continuously wet.
3. Exposed part of the block shall be given two coats of oil paintings, lettering as per the
directions of Engineer in charge.
3.26.5 MODE OF MEASUREMENT AND PAYMENT.

The contractor shall be paid for one Boundary /Guard/Chainage block inclusive of
excavation, concrete oil painting and lettering.
207
3.27 PROVIDING AND FIXING CANAL INFORMATION BOARD OF 1.2
x 0.75m. (Item no. CC 43)
providing and fixing canal information board of 1.2x0.75m prepared on 16 gauge M.S
sheet with angle iron frame for size 35x35x3mm with cross bracing of size 25x25x3mm
including painting with one coat of zinc chromate storing primer and two coats each of
green/white back ground and backside grey store enameled bonded with red retro
reflective sheet Engineering grade border/ letter/numeral/arrows coated with non pealable
crystal clear protective transparent coat retaining 100% reflection including two angle
iron post of size 50x50x5mm of 3.65m long inflated at bottom drilled on top and painted
in white and black bonds of 30cm with four numbers high strength of G I bolts and nuts
of size 10mm dia. and 20mm long sheet and angle iron post in one piece without joints
on including all taxes conveying, fixing in ground with cement concrete in M-15 block
of size as directed by Engineer-in-charge.

The work covered by this item shall consist of furnishing of all materials, equipments and
labours for providing and fixing canal information board of 1.20mx0.75m of M.S sheet,
vertical post angle, board frame, cross bracing including fabrication, excavation, fixing
in concrete block of size 60x60x75cm painting, lettering as per instructions of Engineer
in charge and size as mentioned in the description of the item.
3.27.3. MATERIALS:
Structural steel used for information board shall conform to IS228 and IS8910.Material
for concrete shall conform to specification of concrete.
3.27.4. SEQUENCE OF EXECUTION

1.Fabrication:
Fabrication shall generally be done as specified in IS 800.The steel as specified shall be
straightened and cut to correct lengths and measured with steel tape. The cut ends
exposed to view shall be finished smooth. No two pieces shall be welded or otherwise
joined to make up the required length of member.
2. Painting:
All surfaces which are to be painted shall be dry and thoroughly cleaned to remove all loose
skin and rust. A priming coat of approved Steel primer such as red oxide / zinc chromate
primer conforming to IS 2074 shall be applied and two coats each of green/white back
ground grey stone enameled bonded with red retro reflective sheet Engineering grade,
border/letters numerals/ arrows coated with non pealable crystal clear protective
transparent coat retaining 100% reflection as directed by Engineer in charge.
3.Fixing /Erection:
The information board shall be erected and fixed in ground with concrete in M-15 of
block size mentioned in the item above. Any excavation required for fixing in concrete
block shall be done by contractor at his cost.
208
3.27.5. MODE OF MASUREMENT
The information board Shall be measured in number. The item includes all material,
fabrication, painting and fixing in in position as mentioned in the item and as directed by
Engineer in charge.
3.27.6. MODE OF PAYMENT

The payment shall be done on 1 number basis.
209
3.28 PROVIDING AND LAYING RUBBLE SOLING BELOW
FOUNDATION IN LAYERS (Item no. CC 44)

Providing and laying rubble soling below foundation in layers including filling with
rubber chips, murum etc. complete.

This item shall consist of furnishing of tools, equipments, materials and labour required
for providing and laying rubble soling below foundation in layers including filling with
chips and murum.
3.28.3 MATERIALS.
1. Stones for soling shall we sound, hard, dense and durable and resistant to weathering
action reasonably fine-grained uniform in color and texture and free from seams,
cracks or other defects which would adversely affect their strength, durability and
appearance.
2.Size
The dimension of the stone to be used shall not weigh less than 35 kg each. Chips
however will be used to make rubble soling as dense as possible. Total volume of
chips will be 5 To 10% of masonry.
3.Test for good stones.
Before any quarry for a stone is approved it shall be seen that beside satisfying the
specification mentioned in in para 1.3.1 above stone shall be such as will not absorb
water more than 5% of its weight after keeping it under water for 24 hours.

1.Preparation foundation prior to laying
Immediate before rubble soling is started the foundation shall be thoroughly cleaned
of loosematerial including all chips, dirt’s etc. This shall be done with the help of stiff
brooms and water.
2.Laying.
The stones shall be laid carefully on flat bed of prepared foundation in layers. The
interstices shall be filled with rubble chips and murum so as to get a dense rubble
soling.
3.28.5 MODE OF MEASUREMENT AND PAYMENT

The item will be measured and paid on one cubic metre basis.
210
3.29 BACKFILLING UP TO GROUND LEVEL BEHIND THE CANAL
STRUCTURE (Item no. CC 45).
Backfilling up to ground level behind the canal structure etc complete with suitable
material of approved quality in layers not exceeding 20cm without disturbing the
structure etc complete excluding watering and compaction.

Backfilling generally means excavation refill up to the ground level by embankment
material which is required to be placed in excavation after the structure is built up above
the normal ground level. All the back fill shall be carefully graded to the lines and grades
as shown on the drawing or as directed.
3.29.3 MATERIAL
The material obtained from the excavation work in this contract will be allowed to be
used for backfilling if of approved quality free of cost. Material shall satisfy the
specification for embankment.
3.29.4 SEQUENCE OF EXCAVATION.

All loose material and surface debris shall be removed. The bed and sides shall be
drenched with water sufficiently as to prevent absorption of water from back fill material.
Backfilling shall be done in layers with materials obtained from the excavation.

The measurement of widths for payment will be taken as between the accepted payment
lines of the excavation under the respective excavation items and face of the masonry or
concrete structures. The back filling may not have to be done right up to the original
ground level. The work will be paid for only up to the depth of backfilling as required
and directed by the Engineer in charge. Deduction in quantities of backfill shall be made
for shrinkage at the rate 10% of intermediate measurement and 5% for final measurement
of backfill.
3.29.6 MODE OF PAYMENT.

The rate for this item shall be for unit of one cubic metre.
211
3.30 Providing and constructing contraction joints (Item no.CC 46).
Providing and constructing contraction joints by fixing 310mm wide central bulb type
of approved quality PVC water stop in two lines with 8mm dia. steel dowel rods on
either side at 1m interval, forming 125x 125mm size groove in between 2 water stops
for filling asphalt, fixing 15mm dia., two legged G.I pipe with U- bend at bottom for
circulating steam at interval and forming 150mm dia. formed drain behind water seals
including cost of all materials , machinery, labour, filling asphalt in groove , circulation
of steam at intervals valcanizing water seal joints etc. complete with all leads and lifts.

This item includes providing and construction of contraction joints by fixing 310mm
wide central bulb type of approved quality PVC water stop with steel dowel rods,
formation of grooves, filing asphalt etc. with all material, labour, equipments and all other
work as mentioned in the item.
3.30.3 MATERIAL:
P.V.C water stops shall conform to IS 1838/61 and shall satisfy following specification.
They shall be self extinguishing anticorrosive, chemical resistant and shall have no effect
of alkalis out of atmospheric action and shall have good bondage with cement concrete.
The water stops shall be of approved manufacture and shall have
I) Specific gravity 12.50

II) Tensile strength 140kg/sq cm
III) Elongation at break 350
IV) Shore hardness “A” 75
All other material shall conform to IS standards.

1.The P.V.C strip/ shall be laid as shown in drawing and as directed by the Engineer in
charge.
2.JOINTING: The process of lapping and vulcanizing is to be done for jointing water
stoppers. Steam circulation is to be done for every 10 to 12m height of jointing.
Wooden templates with suitable grooves at 45 ̊ and 90 ̊ angle shall be used for cutting
the water stops.
3. P.V.C water stops shall be cut to required angle by sharp knife.
4.The metal strip shall be heated with a blow lamp to a temperature of 200 C and both
ends of P.V.C shall be kept sticking to the hot metal strip and edges shall be allowed
to melt. Metal strip shall then be removed, both ends shall be pressed together and
allowed to cool.
5. A Groove between two water stops shall be filled with asphalt.
212
3.30.5 MODE OF MEASUREMENTS AND PAYMENT.
The unit of payment shall be per running metre length arrived at by measuring the length
of joints.
213
3.31. SPECIFICATIONS FOR BITUMINOUS GEOMEMBRANE LINING
A Bituminous Geomembrane (BGM) is an excellent waterproofing material
which is practically impervious. It is manufactured by impregnating a non-
woven polyester geotextile with an elastomeric bitumen compound. The BGM
composites contain internal non-woven polyester reinforcement from 200 g/m2
up to 400 g/m2 and overall thickness of the composites are from 3.5 mm up to
5.6 mm which allows this to be used without any protective cover such as earth/
concrete.
This durable composite is an effective waterproof and gas-impermeable
separation layer with significant properties like UV resistance, workability at
temperatures -40 to 55 °C, mechanical / puncture resistance, flexible, stable
against alkali and acidic medium, suitable for potable water, dimensional
stability and mechanical workability, easy installation, welded and repaired by
local crews or maintenance people of any client.
3.31.2. Scope of work

This specification covers the requirements for providing and supplying of
Bituminous Geomembrane as hydraulic liner including all statutory duties,
insurance, transportation and third party inspection charges of agency approved
by WRD, excluding taxes levied by Government of India and Government of
Maharashtra in all respect.
3.31.3. Material Specifications
3.1 Introduction:
The term geomembrane refers to all geomembranes intended for civil
engineering structures. Geomembranes are thin, flexible, seamless, and
impermeable in all circumstances, according to Darcy’s Law (coefficient of
permeability below 10-13 m/s) and retain their properties even when in service.
BGM is based on the combination of a non-woven polyester geotextile for
mechanical resistance, and a specifically designed bituminous binder that
guarantees waterproofing, chemical resistance and ageing behavior.
214
Bituminous Geomembrane Structure
3.2 Applications: Bituminous Geomembrane is widely used as waterproofing
barrier in the below listed areas.
Hydraulic uses
• Dams
• Channels
• Irrigation canals
• Navigation canals
• Reservoirs and basins
• Banks protection
Environment uses.
• Solid waste storage
• Domestic waste containment
• Industrial or mining waste covering
• Polluted snow storage area
• Compost area, clinkers containment pad and other wastes
• Liquid waste storage
• Decantation Dam for polluted water
• Decantation Pond for polluted water
• Protection against agricultural pollution
3.3 Applicable ASTM codes:

The manufacturing, supplying, and testing at work sites of Bituminous geomembrane
shall comply within range of following physical and mechanical properties of Type-
A BGM as per with below listed ASTM standards and codes.
215
216
3.31.4 Unloading.
4.1 Access
Before unloading, access conditions to the site must be studied carefully to bring
in the rolls correctly to avoid wasting time. The main concern is room! Delivery
trucks and machinery (loader, forklift, crane or excavator) need to be able to
turn; bear in mind that they could have special additional equipment (such as an
unloading pin or Unloading beam).
4.2 Delivery of rolls

Usually, the delivery will be carried out by regular 20’ sea-containers each
containing 9 rolls maximum.
BGM rolls in container
217
Rolls of BGM each having 5.1m width and of required length, thickness
manufactured, wrapped over a steel mandrel of 5.47m long (refer fig below) and
transported from factory location to site. For the unloading of BGM rolls from
containers, fabrication of special unloading Pin or unloading beam is must
keeping in view the load and dimension of each roll.
3.31.5 Storage of BGM rolls

On the ground, each roll occupies a surface of 5 m², thus sufficient area should
be available at site as per the number of BGM rolls. Additional space is also
required for handling depending on the vehicle used (shovel, crane, loader or
crane truck etc).
Dimensions of BGM roll with mandrel.

On the ground, each roll occupies a surface of 5 m², thus sufficient area should
be available at site as per the number of BGM rolls. Additional space is also
required for handling depending on the vehicle used (shovel, crane, loader or
crane truck etc).
The rolls should not be stored directly on the ground due to risk of punching on
several layers of the roll. When storing rolls, the distance between the bottom of
the roll and that of the mandrel, which is approximately 35 cm, must be taken
into consideration. They should lay on adapted rigid supports such as:
• Concrete blocks
• Wooden beams
• Metal trestles or I-beams
218
Different types of supports for the storage of BGM rolls
3.31.6 Methodology of execution.
6.1 Subgrade Preparation
Before installation of BGM, it must be ensured that the slope and base of canal
bed (subgrade) is properly compacted, and the subgrade must be inspected to
ensure there are no sharp edged aggregates. After compaction, the ground is
sterilized where plant growth could cause problems, especially near anchorages.
The subgrade preparation is done by filling the base and slope with morrum or
locally available material at appropriate moisture content and compacting it
uniformly using a plate compactor as shown in figure below.
219
Subgrade Preparation before BGM installation
6.2 Trench Excavation
The anchorage trench with depth and width as shown in figure below should be
excavated at the top edge of both the banks of canal to immediately anchor the
membrane with anchor bar 12mm diameter and spacing @ 0.75m c/c along the
canal length.
Trench Excavation for BGM at canal banks
6.3 BGM Laying
For the purpose of installation of BGM at the canal, a manual installation beam
need to be fabricated of the required capacity and dimension. There is a green
marking indicator at the BGM roll as to where to place the overlap for full uncut
rolls and to and easily guide the workers when laying the strips. For cut rolls, it
is necessary to mark the position of the membrane with builder’s line or painted
marks, to define a minimum 20cm overlap.
220
Laying of BGM sheet by installation beam
Also during installation, it is always ensured that the overlapping of BGM over
the other is done in canal flow direction as shown in below figure.
The laying of BGM should be carried out with the terphane (clear plastic film)
downwards and the sanded face upward. The sanded face helps in stable
movement of construction personnel and the terphane film is anti-rooting film,
which protects the penetration of vegetation from subgrade to BGM.
Overlapping of BGM layer
A gang of about 20-25 persons is required to pull the BGM from the installation
beam upto the other bank top of canal. The installation beam is supported by a
crane staying at one bank top of canal. Another gang of four persons would
install the anchors by hammering into the trench and then immediately
backfilling with compacted earth along the trench except at the location of over
lapping. This location would later be torch welded and then anchored and
backfilled.
221
6.4 Trench Anchorage
The proper execution of anchoring at the crest is essential to the behaviour of

the geomembrane and to prevent creases along the slope. The trench prepared at
both the banks in advance to avoid unnecessary and potentially damaging
movements of the membrane as explained earlier for anchorage of BGM at both
banks.
Details of Anchor Dowel
6.5 Welding/Torching
After laying of BGM with proper overlapping in the flow direction, torching of
overlapped part is done in order to ensure the monolithic behavior of two
separate roles. A typical manual welding crew includes:
• a welder, a helper for rolling
• An additional worker is needed for seam preparation (clear dirty
membranes exposed to mud or wind, etc.). The welder leads the whole
operation, setting the pace and directing the helper.
222
6.5.1. Welding Equipment
The equipment required for manual welding includes:
• Propane/LPG gas torch with a 4-hole flat burner, attached with a lance and
a trigger handle with adjustable flow.
• LPG gas cylinders, with a hand truck and an adjustable pressure valve
between 0 and 3 bars.
• Flexible gas feed pipe that is long enough to allow welding of a whole strip
without having to move the propane gas bottle. Heatproof gloves in
accordance with regulations.
• Small trowel and Fire extinguisher with powder or carbon dioxide.
Installation kit
6.5.2. Cleanliness of Weld
• The surface to be welded must be clean to ensure no defects and a proper

mechanical resistance in accordance with specifications.
• Visible mud traces must be cleaned with a sponge.
• Any sharp stones that may still lie under the lower geomembrane must be
removed, as their presence would hinder the proper rolling of the seam.
223
6.5.3. Detailed Procedure of Welding
The procedure for welding is as follows:
• Remove any sharp stones that may still lie under the membrane, as their
presence would hinder the proper rolling of the seam.
• Carefully brush the seam area to remove loose sand.
• Clean mud traces with a sponge.
• Remove the PE silicone film after the seam area has been cleaned.
• Carefully burn in advance the terphane film where present, after turning
the membrane upside down.
• First, weld a 50cm long area, and roll the roller on it carefully to join the
two strips together.
• While moving at a continuous steady pace with one hand or a hook, lift the
upper membrane about 10cm and insert the torch between the two strips,
while keeping the flame aligned with the edge in order to heat the 20cm
width in one single run.
• Carry out the rolling 1.5 or 2.0 meters behind the burner, about 1.0 meter
behind the flame.
• The torch must be tilted so as to simultaneously melt the bitumen on both

surfaces.
• The welder heats the overlapping surfaces until the bitumen begins to melt
(stop before the bitumen melts completely or begins smoking).
• The entire width of the overlap must be welded.
• The welder lowers the top geomembrane onto the bottom geomembrane,
which may leave a few wrinkles in the overlap.
6.6 Rolling
Few minutes after the welding operation, the assistant welder presses down on
the overlap with a roller, making sure the wrinkles are removed. Rolling is then
carried out about 1 m behind the flame.
224
Torching and rolling of overlap joints
A bitumen edge must ooze when rolling, on a width up to 3 cm – visual proof of

good quality weld. The welder then adjusts his forward speed and the torch
power to control the amount of heat applied to the seam.
Finishing of welds joints

Once the strip is finished, cooled down and visually inspected, the welder
proceeds to the finishing works, through reheating the edge and shaping it as a
fillet, with a small trowel.
Finishing of welded joint
225
3.31.7. Testing
Third party inspection for physical and mechanical properties of BGM rolls are
mandatory. Third party inspection agencies will be decided by the Hon. Chief
Engineer after the work is awarded. Contractor may suggest three names of
reputed third-party inspection agencies.
The testing of BGM rolls shall include the following tests.
• Thickness (mm)
• Width (m)
• Mass per unit area (kg/m2) in accordance with ASTM D 3776.
• Tensile strength (N/mm) in accordance with ASTM D 7275.
• Elongation (%) in accordance with ASTM D 7275.
• Static puncture (N) in accordance with ASTM D 4833.
3.31.8 Mode of measurement

All measurements shall be taken on cross section of canal. For this purpose,
detailed cross section of the canal bed shall be taken at the interval of 30 m. or
less as directed before a particular reach starts. The Contract rate shall be in sq.m
of the BGM used. The measurements should be inclusive of overlap and
minimum overlap between joints should not be less than 200mm. The final area
should include the cross section of canal and overlaps complete.
The unit of measurements shall be per square meter. The unit rate includes,
• Manufacturing & supply cost.
• Transportation up to site
• Third party inspection & testing charges.
• All taxes
226
For Office Use Only
SECTION 4
SPECIFICATION FOR TUNNEL
2022-23
227
SPECIFICATION FOR TUNNEL
4.1 EXCAVATION OF TUNNEL IN ALL TYPES OF ROCK

THROUGH ADIT / ITSELF & SHAFT (Item No.TN01, TN02 &TN03)
Excavation of tunnel in all types of rock through adit / itself & Shaft by drilling and
smooth control perimeter blasting, mucking, disposing muck in muck yard, lighting,
ventilation inside tunnel including dewatering considering cross section of tunnel as
D-shaped with initial lead of 1.5 Km for adit & Shaft (From average face to Dump
yard including length of Adit) / 750m for Shaft (From top of shaft to Dump yard)
etc. Complete.
4.1.2 Scope of work
The excavation in all strata includes soft and hard murum, soft and hard rock, faults,
fissures, shear zones etc. The items covered under these specifications are as under:
Excavation by tunneling in all strata such as soft and hard rock etc. including drilling
and smooth controlled perimeter blasting and depositing the excavated materials in
a systematic way specified by the Engineer-in-charge complete with all lifts and
leads for all underground excavation.
The excavations shall be made according to the exact shape, lines and grades shown
on the drawings and instructions of the Engineer-in-charge.
The specifications in this section cover underground excavation by tunneling for the
horizontal and inclined tunnel, muck pit, intake tunnel, intake structure,
interconnecting tunnels, tail surges, shafts, galleries etc. between the two caverns,
head race tunnel, tail race tunnel, etc. complete.
The work to be done under these specifications shall consist of the following items
i) Furnishing all tools, equipment, machinery, plant, labour and material necessary
for carrying out excavation by smooth/ controlled perimeter blasting including
loading, transportation and disposal of excavated materials to specified dump yards.
ii) Preparation and maintenance of haul roads.
iii) Maintaining adequate lighting, ventilation, drainage, signaling arrangements etc,.
iv) Providing safe support systems either permanent or temporary to all underground
excavations and providing all facilities for instrumentation.
v) Undertaking necessary safety measures for all workmen, supervisory staff and
inspecting personnel.
228
vi) Providing all necessary arrangements and facilities for inspection & measurement
checking.
vii) Undertaking necessary measures to maintain noise and dust levels within limits
for efficient and trouble free working atmosphere in underground work.
The specifications detailed in this section are for excavation to be executed

predominantly by means of drilling and blasting involving the use of the smooth
controlled perimeter blasting techniques. However the contractor may propose any
alternative method and submit to the Engineer together with all pertinent details such
as its types and characteristics, for approval of Engineer. Only on specific approval
of Engineer-in-charge, modified blasting techniques shall be adopted.
The excavation of the intake tunnel, muck pit, intake structure, head race tunnel,
surge, expansion gallery and connecting tunnel shall be done carefully by
smooth/controlled perimeter blasting technique so as to ensure smooth and
unshattered roof and walls.
A) EXCAVATION OF TUNNEL OR CAVERNS:
The excavation of two caverns shall progress downwards in slices. The complete
excavation operations shall be divided in to several stages of drilling and blasting in
which the following principal method shall be used.
• Central point tunnel/exploratory drift in the Tunnel roof.
• Side stepping, on either side of the pilot tunnel, up to full width of the tunnel.
• Horizontal benching and
• Vertical benching.
B) HEADING:
The topmost slice called the heading shall be up to the floor of the exploratory drift.
This top slice shall be excavated in two portions, one on each side of the exploratory
drift, covering the entire width of the tunnel as directed by the Engineer-in-charge.
Careful smooth/controlled blasting method shall be used to excavated the top heading
to pre serve the integrity of the roof and to avoid the formation of any crack zones
beyond the roof arch.
As soon as blasting is done in any of the portions, muck shall be hauled away, scaling
carried out and the rock bolts installed and tightened if required. Broad sequences for
placing the designated support shall consist of installation and tensioning of rock
bolts first of all immediately after excavation application, of first layer of scaling shot
Crete if ordered by the Engineer's representative, when excavation heading is 10-15
m. away, placing of wire mesh, retightening and grouting of bolts and application of
second layer of shotcrete.
229
C) BENCHING:
Bench excavation shall start only after the entire arch of the tunnel exposed and all
necessary operations including installation of instruments in the roof have been
completed to the satisfaction of the Engineer-in-charge. No extra payment shall be
made for such operations, involving additional efforts and expenditure if required to
be carried out later on, on the request of the contractor.
• First Bench:
Enlargement of the tunnel shall now be initiated by benching. The first bench below
the top heading may be a horizontal bench.
• Vertical Bench:-
Subsequent to the top heading and the first bench, all subsequent enlargements shall
be done through vertical benching to obtain a smooth contour on the tunnel walls, the
vertical bench shall be limited to a height of 4 m to facilitate easy excavation,
geological mapping and installation of wall support.
If the contractor wishes to adopt higher bench, he shall furnish to the Engineer-in-
charge his detailed analysis to show that with the equipment available with him, he
is capable of carrying out all operations related to excavation and supporting, in a
short time without damage to the wall rock satisfying the provisions of Para
concerned.
Above details are only indicative and the contractor shall furnish for approval of
Engineer a scheme of excavation to achieve the desired progress of excavation to
comply with the requirements of the obligatory milestone dates for his item.
D) EXCAVATIONS OF INTERSECTIONS AND JUNCTIONS:
Special care and precautions shall be taken to carry out excavation of intersections
and junctions to avoid over-breaks. Spacing of the contour holes in the drilling pattern
shall be reduced and the bank blasted last in the zones adjacent to the final excavation
line to get the desired results.
Whenever a tunnel intersects the cavern, the tunnel shall be stabilized in advance by
several rows of closely spaced rock bolts around the perimeter connected with mesh-
reinforced shotcrete. The rock bolts may need special orientations according to the
instructions of the Engineer-in-charge. If a tunnel is to be excavated from the cavern
wall, a series of closely spaced grouted bars shall be installed around the tunnel
perimeter (Before starting tunnel excavation) to reinforce the rock prior to
excavation.
E) EXCAVATION OF AUXILIARY FACILITIES:
In order to complete the construction of the underground works in the prescribed

time, it may be necessary to drive auxiliary tunnels not included in the schemes of
works put to contract. The contractor shall propose the location of such tunnels so
230
that the stability or operation of any present or future work is not disturbed. The
Engineer-in-charge will study the proposal and may approve or reject contractor’s
proposals. The approval of the Engineer-in-charge does not in any way absolve the
contractor from his responsibility for damages and inconveniences that may arise
from the excavating of such tunnels.
Incase auxiliary tunnels are proposed, all their costs and necessary time for their
execution shall be appropriately included in the contracted rates for the main relevant
items of the excavation of the element and be executed in the contract period of the
corresponding works that they intend to serve. There shall be no separate payment
for such auxiliary tunnels on any account.
4.1.3 Material Specifications
4.1.3 .1 Electric Detonators
While using electric detonators the contractor shall install lightening detectors that
will provide uninterrupted information about the atmospheric electric activity. It
would be a good practice to install alarms directly connected to the detectors at each
work front when explosives are being charged at a front where electric detonators
are used and a storm is detected. The personnel shall be quickly moved at a prudent
distance until the atmospheric conditions become normal.
A) EXPLOSIVE AND BLASTING
The contractor shall acquaint himself with all the applicable laws and regulations
concerning storing, handling and the use of explosives. All such laws, regulations
and rules etc., as are current from time to time shall be binding upon the contractor.
The provision detailed in this are supplementary to the above laws, rules and
regulations etc. and are applicable except where they conflict with the above
mentioned laws etc. from time to time. Further, the Engineer-in-charge may issue
modifications, alternations and new instruction from time to time. The contractor
shall comply with the same without these being made a cause for any claims.
All material such as explosives, detonators, fuses, tamping materials etc. that are
proposed to be used in the blasting operations, shall have the prior approval of the
Engineer-in-charge.
Black Powder and safe explosives (as commonly current in India) shall be used
wherever possible. Explosives with nitroglycerine shall be used where the above
explosive are not effective.
The use of fuse with only one protective coat is prohibited. The fuse shall be
sufficiently water-resistant and to be unaffected when immersed in water for thirty
minute. The rate of burning of the fuse shall be uniform and not less than 4 (four)
seconds per 25 mm of length with 10%(Ten percent) tolerance on either side.
231
Before use the fuse shall be inspected and moist, damaged or broken ones should
be discarded. The rate of burning of all new types of fuses, or when they have been
in stock for long, shall be tested before use.
The detonators used shall be capable of giving an effective blasting of the

explosives. Moist or damaged detonators shall be discarded.
B)PERSONNEL:
Excavation by blasting will be permitted only under personnel supervision of

competent and licensed person and trained workmen.
All supervisors and workmen in charge of makeup, handling, storage and blasting
work shall be adequately insured by the contractor.
The storage shall be in charge of a very reliable person, approved by the Engineer-
in-charge, who may if necessary, call for his police enquiry being made as to his
reliability, antecedents etc. The contractor shall have to produce a security for the
person in charge of the explosives, as and when required by the Engineer-in-charge,
or the Civil Authorities of the District.
The contractor shall make sure that his supervisors and workmen are fully
conversant with all the rules to be observed in storing, handling and use of the
explosives. It shall be assumed that the supervisor in charge, is thoroughly
acquainted with all the details of the handling and the blasting operations.
C) STORAGE OF EXPLOSIVES:
The contractor shall build a magazine for storing the explosives. The site of the
magazine, its capacity and design shall be subject to approval by the Engineer-in-
charge and the Inspector of Explosives before the construction is taken up. As a
rule, the explosives should be stored in a clean, dry, well-ventilated, bullet proof
and fireproof building, on an isolated site.
The explosives, detonators and fuses shall each be separately stored.
A careful and day to day account of the use of explosives shall be kept by the
contractor in an approved register in an approved manner. The register shall be
produced by the contractor for the inspection of the Engineer-in-charge when so
required by the later. The Engineer-in-charge may also pay surprise visit to the
storage magazine. In case of any unaccountable storage of the explosives or if the
account is not found to have been maintained in a manner prescribed by the
Engineer-in-charge, the contractor shall be liable to be penalized with forfeiture of
security deposit, lodged by him with the Government or his contract shall be liable
to be rescinded in which case he shall not be entitled to any compensation for the
loss, etc. The action taken under this clause shall be in addition to that which might
be taken by the competent civil authorities/ Court of law.
232
The magazine shall at all times be kept scrupulously clean.
No unauthorised person should at any time be admitted inside the magazine.
The magazine shall, when not in use by authorized persons be kept well and
securely locked.
The magazine shall on no account be opened during or on the approach of a thunder

storm and no person shall remain in the vicinity of the magazine, during such
period.
Magazine shoes without nails shall at all times be kept in the magazine and a wood
tub or cement trough about 300 mm high and 460 mm in diameter, filled with water
shall be fixed near to door of the magazine.
Persons entering the magazine, must put on the magazine shoes, which shall be
provided by the contractor for the purpose, and be careful...
• Not to put their foot on the clean floor unless they have the magazine shoes on
• Not to allow the magazine shoes to touch the ground outside the clean floor.
• Not to allow any dirt or grit to fall on the clean floor.
• Persons with bare foot, shall before entering the magazine dip their feet in water and
then step direct from the tub over the barrier (if there be one) on the clean floor.
• A brush or broom shall be kept in the lobby of the magazine, for cleaning out the
magazine on each occasion it is opened, for the receipt, delivery or inspection of
explosives.
• No matches or inflammable material shall be allowed in the magazine. Light shall
be obtained from an electric storage battery lantern.
• No person having articles of steel or iron on him shall be allowed to enter the
magazine.
• Cotton, rags, waste, articles liable to spontaneous ignition, shall not be allowed
inside the magazine.
• Workmen shall be examined before they enter the magazine be see that they have
none of the prohibited articles in their possession / on their person.
• No tools or implements other than these of copper, brass, gunmetal or wood shall be
allowed inside the magazine. All tools shall be used with extreme gentleness and
care.
• Boxes of explosives shall not be thrown down along the floor, and shall be stacked
on wooden trestles. Where there are white ants, the legs of the trestles should rest in
shallow copper, lead or brass bowls containing water. Open boxes of dynamite shall
never be exposed to the direct rays of the sun.
• Empty boxes or loose packing material shall not be kept inside the magazine.
• The magazine shall have lightening conductor, which should be got tested at least
once a year, by an officer authorized by the Engineer-in-charge, the testing fees shall
be a charge on the contractor, at prevailing rates. The contractor shall within 15 days
comply with the same at the contractor’s expense, which shall not be open to
233
question or the Engineer-in-charge may consider any action that he may consider
fit.
A notice shall be hung near the store, prohibiting entrance of unauthorized people.
The following shall be hung in the lobby of the magazine.
(a) A copy of rules both in English and in the languages by which the workers
concerned are familiar with.
(b) A statement showing the stock in the magazine at that particular time.
(c) The certificate showing the last date of testing of the lightening conductor.
(d) A notice that smoking is strictly prohibited.
The magazine shall be inspected at least twice a year by an officer representing the
Engineer-in-charge who shall see that all the rules, are strictly complied with. He
shall notify all omissions etc. to the contractor who shall rectify the defects within
a period of 15 (fifteen) days from the date of receipt of the notice, failing which the
Engineer-in-charge may take whatever action he considers suitable.
D) USE OF EXPLOSIVES:
➢ For the transport of the explosives and detonators between the store and the
site, closed and strong containers made of soft material such as timber, zinc,
copper, leather and like shall be used.
➢ Explosives and detonators shall be carried in separate boxes for the
conveyance of primers, special containers shall be used.
➢ The boxes and containers used shall be kept close.
➢ Explosives shall be stored and used chronologically to assure the ones,
received earlier being used first.
➢ A make up house shall be provided at each working place in which cartridges
will be made up by experienced man as required for the work. The makeup
house shall be separate from other buildings. Only electric storage battery
lamps will be used in this house.
➢ No smoking shall be allowed in the makeup house or generally which dealing
with explosives.
E) DISPOSAL OF DETERIORATED EXPLOSIVES:
All deteriorated explosives shall be disposed off in an approved manner, following

the extant rules. The quantity of the deteriorated explosives to be disposed off shall
be intimated to the Engineer-in-charge prior to its disposal.
F) PREPARATION OF PRIMERS:
The primers shall not be prepared near open flames or fires. The work of preparation
of primers shall always be entrusted to the same personnel. Primers shall be used
as soon as possible after they are ready.
234
G) CHARGING OF HOLES:
The work of charging shall not generally commence before all the drilling work at
the site is completed, and the supervisor has satisfied himself to that effect by actual
inspection. However, if the charging has commenced before all the drilling work at
site is completed, special precaution in handling and keeping explosives and
detonators at loading site shall be taken.
While charging, open lamps, shall be kept away. For charging with powered
explosives a naked flame shall not be allowed.
Only wooden tamping rods, without any kind of metal on them, shall be allowed to
be used. The tamping rods shall have cylindrical ends.
Bore holes must be of such a size that the cartridges can easily pass down them,
they shall not however be too big.
Only one cartridge shall be inserted at a time and gently pressed home with the
tamping rod. The sand, clay or other tamping material used for filling the hole
completely shall not be tamped too hard.
H) BLASTING:
i) General
Blasting shall be carried out in a manner that completes the excavation to the lines
indicated in drawings, with the least disturbance to adjacent material. It shall be
done only with the written permission of the Engineer. All the statutory laws,
regulations, rules, etc., pertaining to the acquisition, transport, storage, handling and
use of explosives shall be strictly followed. Blasting by direct connections to power
supply is prohibited. Blasting shall be carried out only by license holder person.
The Contractor may any method or methods of blasting consistent with the safety
and job requirements. Prior to starting any phase - of the operation the Contractor
shall provide information describing- pertinent blasting procedures, dimensions and
notes.
The magazine for the storage of explosives shall be built to the designs and
specifications of the Explosives Department concerned and located at the approved
site. No unauthorized person shall be admitted into the magazine which when not
in use shall be 'kept securely locked. No matches or inflammable material shall be
allowed in the magazine. The magazine shall have an effective lightning conductor.
The following shall be hung in the lobby of the magazine:
(a) A copy of the relevant rules regarding safe storage both in English and in the
language with which the workers concerned are familiar. .( Act 1884, Explosive
Rules 2008, The Explosive (Amendment) Rules,2019 and as amended from time to
time.)
235
• A statement of up-to-date stock in the magazine.
• A certificate showing the last date of testing of the lightning conductor.
• A notice that smoking is strictly prohibited.
All explosives shall be stored in a secure manner in compliance with all laws and
ordinances, and all such storage places shall be clearly marked. Where no local laws
or ordinances apply, storage shall be provided to the satisfaction of the Engineer
and in general not closer than 300 m from the road or from any building or camping
area or place of human occupancy. In addition to these, the Contractor shall also
observe the following instructions and any further additional instructions which
may be given by the Engineer and shall be responsible for damage to property and
any accident which may occur to workmen or the public on account of any
operations connected with the storage, handling or use of explosives and blasting.
The Engineer shall frequently check the Contractor’s compliance with these
precautions. If more than one agency is working in site, intimation of blasting shall
be given to other agencies well in advance to enable them to take suitable
precautions.
ii) Materials, Tools and Equipment

All the materials, tools and equipment used for blasting operations shall be of
approved type. The Engineer may specify the type of explosives to be allowed in
special cases. The fuse to be used in wet locations shall be sufficiently water-
resistant as to be unaffected when immersed in water for 30 minutes. The rate of
burning of the fuse shall be uniform and definitely known to permit such a length
being cut as will permit sufficient time to the firer to reach safety -before explosion
takes place. Detonator-s shall be capable of giving effective blasting of the
explosives. The blasting powder, explosives, detonators, fuses, etc., shall be fresh
and not damaged due to dampness, moisture or any other cause. They shall be
inspected before use and damaged articles shall be discarded totally and removed
from the site immediately.
iii) Personnel
The blasting operation shall remain in the charge of competent and experienced
supervisor and workmen who are thoroughly acquainted with the details of handling
explosives and blasting operations.
iv) Blasting Operations
The blasting shall be carried out during fixed hours of the day preferably
during the mid-day luncheon hour or at the close of the work as ordered in writing
by the Engineer. The hours shall be made known to the people in the vicinity. All
the charges shall be prepared by the man in charge only.
The Contractor shall notify each public utility company having structures in
proximity to the site of the work of his intention to use explosives. Such notice shall
be given sufficiently in advance to enable the companies to take such steps as they
may deem necessary to protect their property from injury. In advance of any blasting
work within 50 m of an
236
railway track or structures, the Contractor shall notify the concerned Railway
Authority of the location, date, time and approximate duration of such blasting
operations.
Red danger flags shall be displayed prominently in all directions during the
blasting operations. The flags shall be planted 200 m from the blasting site in all
directions. People, except those who actually light the fuse, shall be prohibited from
entering this area, and all persons including workmen shall be excluded from the
flagged area at least 10 minutes before the firing, at warning siren being sounded
for the purpose.
The charge holes shall be drilled to required depths and at suitable places.
Blasting should be as light as possible consistent with thorough breakage of the
material necessary for economic loading and hauling. Any method of blasting which
leads to overshooting shall be discontinued.
When blasting is done with powder, the fuse cut to the required length shall
be inserted into the hole and the powder dropped in. The powder shall be gently
tamped with copper rods with rounded ends. The explosive powder shall then be
covered with ramping material which shall be tamped lightly but firmly.
When blasting is done with dynamite and other high explosives, dynamite
cartridges shall be prepared by inserting the square cut -end of a fuse into the
detonator and finishing it with nippers at the open end, the detonator gently pushed
into the primer leaving 1/3rd of the copper tube exposed outside. The paper of the
cartridge shall then be closed up and securely bound with wire or twine. The primer
shall be housed into the explosive. Boreholes shall be of such size that the cartridge
can easily go down. The holes shall be cleared of all debris and explosive inserted.
The space of about 200 mm above the charge shall then be gently filled with dry
clay, pressed home and the rest of the tamping formed of any convenient material
gently packed with a wooden rammer.
At a time, not more than 10 such charges will be prepared and fired. The
man in charge shall blow a siren in a recognised manner for cautioning the people.
All the people shall then be required to move to safe distances. The charges shall be
lighted by the man-in- charge only. The man-in-charge shall count the number of
explosions. He shall satisfy himself that all the charges have been exploded before
allowing the workmen to go back to the work site.
After blasting operations, the Contractor shall compact the loose residual
material below subgrade and replace the material removed below subgrade with
suitable material.
For lighting the fuses, a lamp with a strong flame such as a carbide lamp, shall be
used. If electric detonators are used, exploder of suitable capacity shall be used for
blasting.
The Supervisor shall watch the time required for the firing of the fuses and shall
see that all the workmen are under safe shelters in good time.
237
I) ELECTRICAL FIRING:
➢ Only the supervisor in charge shall possess key of the firing apparatus and
he shall keep it always with himself.
➢ Special apparatus shall be used as a source of current for the blasting
operations. Power lines shall not be tapped for the purpose.
➢ The detonators shall be checked before use.
➢ For blasts in series, only detonators of the same manufacture and of the
same group of electrical resistance shall be used.
➢ Such of the electrical lines as could constitute danger for work of charging,
shall be removed from the site.
➢ The firing cables shall be with a proper insulating cover so as to avoid short-
circuiting due to contact with water, metallic parts or rock.
➢ The use of the earth as a return line shall not be permitted.
➢ The firing cable shall be connected to source of current only when nobody
is in the area of blasting.
➢ Before firing the circuit shall be checked by a suitable apparatus.
➢ After firing, whether with or without an actual blast, the contact between
the firing cable and the source of current shall be cut off before any people
are allowed to leave the shelter.
➢ During storms, charging with electrical detonators shall be suspended. The
charges already placed in the holes shall be blasted as quickly as possible
but taking all the safety precautions and giving necessary warning signals.
If this is not possible, the site shall be abandoned till the storm has passed.
J) PRECAUTIONS AFTER BLASTING:
After the blast takes place in underground works, the workmen shall not be allowed
to go to the face till all the toxic gases are evacuated from the face.
After the blast, the supervisor must carefully inspect the work and satisfy himself
that all the charges have exploded.
K) MISFIRES:
If it is suspected that, part of the blast has failed to fire or is delayed, sufficient time
shall be allowed to elapse before entering the danger zone. When fuse and blasting
caps are used, a safe time should be allowed and then the supervisor alone shall
leave the shelter to see the misfire.
None of the drillers are to work near this hole until one of the two following
operations have been carried out by the supervisor. Either
(i) the supervisor should very carefully (when the tamping is of damp) extract the
tamping with a workman scraper or jet of water or compressed air (using pipe of
soft material) and withdraw the fuse with the primer and detonator with fuse should
be placed in this hole and fired out, OR
238
(ii) The hole may be cleared of 300 mm of tamping and the direction then be
ascertained by placing a stick in the hole. Another hole may then be drilled at least
225 mm away and parallel to it; this hole should then be charged and fired. The
balance of the cartridges and detonators found in the muck shall be removed.
Before leaving his work, the supervisor should inform the supervisor of the
relieving shift of any case of misfires and should point out the position with a red
cross denoting the same, also stating what action, if any, he has taken in the matter.
The supervisor should also at once report at the office all cases of misfire, the
cause of the same and what steps were taken in connection therewith.
The names of the day and night shift supervisors must be noted daily in the
contractor’s office.
If a misfire has been found to be due to a defective detonator, or dynamite, the

whole quantity of box from which the defective article was taken must be returned
to the office for inspection.
Drilling in holes not completely exploded by blasting shall not be permitted.
L) Adoption of safe working methods and prevention of tunneling hazards :
Adoption of safe working methods
1) The Contractor shall at all times adopt such methods of work as will ensure
structural safety and the safety of labour working in the Tunnel.
2) In the use of explosives for blasting, the Contractor shall strictly abide by the
Indian Explosives Act and the Metalli ferrous Mines Regulations and Rules there
under, as well as of the Act and Rules as may be enacted and laid down by the State
and Central Governments from time to time for such works. The Contractor's
attention is specially drawn to relevant conditions of General Conditions of
Contract.
3) If at any time during the work, the Engineer finds the methods of safety
arrangements inadequate or unsafe, the Contractor shall take immediate corrective
action to set them right as directed by the Engineer. The Engineer's directions in the
matter shall in no way absolve the Contractor of his responsibility to adopt safe
working methods.
4) The tunnels section shall be supported on the roof and the sides as necessary to
ensure safety using steel or timber sets, cross bullies and lagging planks of such
sizes and spacing which in the opinion of the Engineer are required for the safe
supports. The exact locations from which or beyond which point no support work
is considered necessary will be subject to the approval of the Engineer and the
decision of the Engineer in this respect will be final. The Contractor will be
239
responsible to ensure the safety in design and adequacy in strength of supports
provided for roof and sides.
M) Tunnel Hazards :
1) Should any hazards occur, the Contractor should notify the Engineer within 8
hours and the Engineer-in-charge or Committee of Corporation's Engineers as may
be decided by the Corporation will inquire into the circumstances, leading to the
same and assess the extent of responsibility devolving on the Contractor. The
Contractor shall give all reasonable assistance and full information to the Engineer-
in-charge / the Inquiry Committee appointed for this purpose by ED/KRCL. The
findings of the Engineer-in-charge / Inquiry Committee shall be final and binding
on the Contractor.
2) In the case of hazards for which the responsibility does not rest with the
Contractor, wholly or partly, as adjudged in terms of Clause above, the Contractor
shall be entitled to an extension of time as in the opinion of the Engineer is
necessary and also to the payment wholly or partly, as may be judged by the
Corporation for the restoration work at a rate under relevant items of Schedule of
Items, Rates & Quantities or to be mutually negotiated between the Corporation
and the Contractor. The Contractor shall also be under obligation to expeditiously
carry out the restoration work including items of work, which may not be provided
in the Schedule of Items, Rates and Quantities. In case of items of such work, for
which no agreed rates are available in the Schedule of Items, Rates and Quantities,
the same shall be executed at the rates set forth in the Standard Schedule of Rates
of Northern Railway, modified by tender percentage and/or at the negotiated rate
agreed upon and/or at its rate will be fixed by analysis of actual inputs required of
all types including labour & material before commencement of such works.
However, no payment will be made to cover damages to Contractor's equipments,
materials, etc., or for the loss of cycle of operations in tunneling or for idling of any
Contractor's labour & machinery.
3) In the case of hazards, for which the responsibility rests with the Contractor, the
Contractor shall carry out the restoration work and such other works as temporary
supports, hand packing, plugging with concrete, provision of extra or new
permanent supports etc., as considered necessary by the Engineer-in-charge shall
be carried out by the Contractor at his own cost. The Contractor shall always keep
sufficient ready stock of supports to meet the emergencies caused by tunnel
hazards.
N) Safety Precautions :
(1) For drill and blast excavation, only Non-Electric detonators (NONEL type) shall
be used. However, at the discretion of the Engineer in Charge and under special
circumstances, it is decided that electric detonators may be used instead, the
following precautions shall be strictly adopted: A separate circuit, independent of
240
power and light circuits, shall be used for blasting. No electrically energized circuit
shall be installed on the same side of the tunnel with the blasting circuits. All
electric lights or other energized circuits shall be disconnected for at least 70 m
from the point of loading. For loading purposes, the employees shall be equipped
with permissible battery lamps. Adequate warning notices shall be given to all
persons employed indicating the period, or danger at the time of firing and it shall
be the duty of the CONTRACTOR to provide adequate shelters or screens for
protection of workers exposed to risk of injury from the explosion or from flying
material. After the blast takes place in the tunnel, the workmen shall not be allowed
to go to the face till all the toxic gases are evacuated from the face.
(2) Careful and proper scaling after each blast is imperative. The support elements
are considered to be sufficient for the overall stability of the tunnels. However, the
CONTRACTOR shall perform the installation of local rock bolts as required to
prevent loosening of rock blocks in the immediate heading area. Periodical
inspection of the tunnel sidewalls and roof areas shall be performed by the
CONTRACTOR to detect possible cracks or signs of instability of the tunnel
support. Assessment of cracks shall be made in association with the results of the
geotechnical measurements in cooperation with the EnC.
(3) In rocks with rock burst potential, scaling-, shotcreting and rock bolting
equipment must be used which allows to be operated from a safe distance from
newly exposed rock surfaces.
(4) Blasting will be permitted only after proper precautions have been taken for
protection of all persons, work and property.
(5) Drilling, blasting, excavating and shotcreting operations shall be conducted by

methods and with equipment which shall positively control dust, fumes, vapours,
gases, fibers, fogs, mists or other atmospheric conditions. Following each round,
the broken rock or muck pile shall be wetted down sufficiently to prevent excessive
dust during mucking operations.
O) Continuous Working :
(1) To ensure the safety and the security of the works, tunnel excavation shall be
continuous by day and night except as otherwise approved by the ENGINEER.
Shift change has to be at the work face so that continuous work is assured. If the
state of the work permits, intermissions will be allowed at general holiday periods,
provided that the works are secured in a safe condition.
(2) The intermission shall not be allowed to start until all support elements in the
rock class at the particular locations have been completed and the face of any
heading is sealed with shotcrete (minimum thickness 0.05 m), unless instructed
otherwise by the EnC.
(3) Under no circumstances should the tunnel be left in an unsafe condition.
241
(4) The CONTRACTOR shall also carry out all additional support measures which
may be required by the DDC and approved by the ENGINEER.
DRILLING AND BLASTING:
In addition to the relevant provisions of above the following provisions shall also
apply for the excavation of the caverns.
i) All drilling for underground excavations shall be done by wet process.
ii) Controlled contour blasting techniques shall be deployed by the contractor in

benching. It will be followed up with ground vibration measurements and ensure
that the ground vibrations do not exceed the relevant provisions of Para here-in-
below. He shall adjust the drilling pattern, hole depth, charge per hole and the firing
pattern of holes for minimizing the co-operating charge and ensuring most
favorable angle of breakage.
(iii) One half of the tunnel width in a suitable slice of say 6 m length, shall be taken
for blasting at a time.
(iv) Closely spaced perimeter holes shall be drilled vertically along the cavern wall,
followed by an adjacent row of holes (with greater burden and spacing). Alternate
holes in the row of perimeter holes shall be kept empty while the others shall be
lightly charged through introduction of 30 cm long spacers in between the explosive
cartridges.
(v) The ignition pattern shall use a combination of both short delays (MS) and long
delays (HS). However the contractor shall evolve his own blasting plan, within the
framework of the principles governing the controlled contour blasting technique
through test/ trial blasting, duly backed up with measurements of peak particle
velocity (ppv) and get it approved from Engineer-in-charge.
Ramps provided for excavation of the tunnel should be removed with maximum
care and precautions.
Modifications could be required in the schedule of excavation of the tunnel

according to the magnitude of deformations recorded by the monitoring system.
The contractor shall rearrange the excavation and supporting schedule to effect
necessary modifications according to the instructions of the Engineer-in-charge.
The Engineer-in-charge may require the contractor at any time to stop bench
excavation and install additional bolts or extra layers of shot Crete in case the exist-
ence of large rock wedges or unstable rock conditions are observed or indicated by
the monitoring system.
242
4.1.3.2 Core Samples
Reports of the Geologists and core samples can be seen in the office of the
Engineer-in-charge. The contractor is however to make his own assessment of ex-
pected ground conditions. Government does not take any responsibility for any
variations that may be detected in actual excavations.
A) Presentation
The contractor shall establish at suitable points, permanent reference marks on the
center lines of caverns, tunnels, shafts etc. and on their extensions at both the ends
as may be necessary to the satisfaction of the Engineer-in-charge. Suitable perma-
nent reference marks shall also be established at portals, adit, shafts etc. as directed
by the Engineer-in-charge. The permanent marks shall be inscribed on
bronze/copper pegs/ plates set in suitably located and adequately constructed
concrete blocks where they will be free from the likelihood of any disturbance. As
the work progresses, centre line marks shall be made on pegs/ plates inserted into
the roof of tunnel and other hollow cuts at convenient intervals for checking
alignment, grades, levels etc. and also the dimensions of the "minimum excavation
lines" to the satisfaction of the Engineer-in-charge. The contractor shall remain
responsible at all times for the sufficiency and accuracy of all such bench marks and
reference points.
The cost of these shall be deemed to have been included in the contract rates for
excavation.
B) ACCURACY OF ALIGNMENT, GRADES, LEVELS ETC.
Bench marks and fixed reference points, with the values of the levels and the
coordinates have been already fixed by Government in the work areas. Plans
showing the position, co-ordinates and levels of these points and the co-ordinates
and levels of the salient points of the various underground works will be supplied to
the contractor on request. The contractor shall fix his permanent points and bench
marks in relation to these. He shall take all precautions to see that the points fixed
by Government are not disturbed by his work and shall make good the damage, if
any, at his own cost.
The contractor shall excavate the tunnels, shafts, caverns, etc. true to alignment,
grade and levels and shall check these at frequent intervals as the work progresses.
The contractor shall provide, free of cost, all facilities like labour, instruments etc.
and all co-operation to the Engineer-in-charge to check the alignment, grades, levels
etc. whenever and every time he is asked for. Such checking by the Engineer-in-
charge shall not absolve the Contractor from his responsibility of maintaining the
accuracy of the works. Any discrepancy or error detected during the course of
excavation and/or at the end of the work when the faces meet shall be set right by
the Contractor at his own cost in a manner satisfactory to the Engineer.
C) REMOVAL AND HAULING OF MATERIAL FROM UNDERGROUND:

Materials from the excavations shall be hauled and disposed off as stipulated earlier
in item. The movement of vehicles shall require a detailed planning and specialized
243
system of signals in order to avoid accident. The traffic planning for transport of
excavated material within the tunnel shall be made in such a way that the excavation
remains as far as possible, free of heavy vehicles most of the time, in order to reduce
interference to all other vehicles of the Government and other agencies to a
minimum. The system of signals shall either be automatic or manual but shall permit
direct communication between both ends of the tunnel so as to know the number of
circulating vehicles in both directions. Costs and expenses caused by such
restrictions, special studies, system of signals etc. shall be included in the contract
rate for excavation.
D) SMOOTH / CONTROLLED PERIMETER BLASTING:-

"The smooth blasting" will require closely spaced contour holes, carefully aligned
and lightly loaded to obtain satisfactory smooth blasting results. A well excavated
surface should show on the rock face the traces of at least 75% of the drill Holes,
traces distributed uniformly in the peripheral rock surfaces exploded by each round,
after scaling down of all loose and shattered rock liable to fall before or during rock
reinforcement (i.e. rock bolting etc.) installations. Closely spaced holes shall be
drilled along the final perimeter of the excavation and are blasted in a single round
along with the production holes using suitable delay detonators in between
alternatively.
A bank of about 0.8 to 1.00 meter shall be left along the periphery of the tunnels in
the previous blast and this bank would then be blasted after drilling closely spaced
holes along the perimeter, in the next round of the blast along with its production
holes. The method which will give best results shall be adopted.
The drilling and blasting pattern shall be decided in consultation with the Engineer-
in-charge and after trial blasting to suit the actual rock conditions. Whenever rock
conditions change, new trial blasts shall be carried out, if necessary to establish a
suitable drilling and blasting pattern to the satisfaction of the Engineer-in-charge.
The tentative recommended diameter of peripheral holes and charging patterns for
controlled perimeter blasting for all excavations are as under:
Drill hole diameter All Tunnels and Shafts Drill hole spacing for
house caverns
38mm 45 to 55 cm 15 to 30 cm
50 mm 55 to 65 cm 20 to 40 cm
The exact drill hole spacing within the above range shall be adopted in consultation
with the Engineer-in-charge.
The contractor shall use such blasting methods that will give reasonably smooth
surface in the roof and walls of the tunnel so as to cause the minimum possible
disturbance to the surrounding rock. The contractor may try a combination based on
his earlier experience elsewhere, if he has any. The optimum spacing of the
perimeter holes and the amount of explosive in them shall be determined by means
of in situ tests. These tests shall be made as many times as necessary until
satisfactory results are obtained. These tests shall be made simulating the condition
of the final excavations.
The tests shall be executed inside the tunnel but in no case test blasting close to the
boundaries of these excavations shall be allowed.
A register showing the diameter, length and spacing of drill holes for blasting
shall be maintained by the contractor in the proforma prescribed by the Engineer-in-
charge which shall be signed by the authorised representatives of both the Engineer
244
and the Contractor. The contractor shall normally use indigenously available
conventional explosives for controlled perimeter blasting. Unconventional
explosives shall be acceptable provided that the contractor gives full details
regarding their effectiveness and demonstrates their suitability and obtains prior
approval of the Engineer. In case such a product is required to be imported, the
contractor shall arrange for its procurement within the limit of the foreign exchange
granted under the contract.
E) STOCK PILING AND DISPOSAL OF MUCK:
Suitable materials out of the excavation, if approved or directed by the Engineer's

representative shall be used, in temporary works as for making platforms, for the
stock piles etc. Useful materials like; riprap for pitching, rubble for masonry or for
crushing should be separated out and stacked as directed. The balance of the spoils
except that required for the backfilling, shall be removed deposited and spread on
dump areas as shown in the drawings or as directed by the Engineer-in-charge in a
neat and orderly manner commencing from the farthest end and coming nearer to
the faces of the tunnels/shafts. No materials shall be dumped where it will spoil the
aesthetics of the site or interfere with accessibility of complete structures, nor shall
any materials be dumped where they may be carried by flood water and obstruct the
natural course of the river. Dump areas shall be leveled and trimmed to reasonably
regular lines, all work shall be done with reasonable neatness. Excavated materials
shall not be carelessly thrown over the work area but should be deposited directly in
permanent positions, so far as consistent with proper excavation of the work. The
useful materials taken out as stated above, may be used in masonry or concrete as
the case may be, free of cost.
All costs of disposal and transportation of muck shall be deemed to be include in the
unit prices for underground excavation. The contractor can dump materials at the
specified disposal areas only when there are no possibilities for its use by the
Government.
F) SCALING AND TRIMMING OF ROCK:

After the face is blasted, gases removed and the face ventilated and lighted, all loose
or loosened rock from the top and sides shall be removed quickly by approved
methods to avoid danger to workmen and equipment. If any loose or loosened rock
is notified anywhere in the excavation it shall be removed expeditiously.
As the work advances, trimming rock surfaces remaining within the minimum
excavation line shall be undertaken simultaneously. In no case shall trimming be
postponed and left to be tackled later on. The cost of such scaling and removal of
loose and loosened rock, trimming etc. shall be deemed to be included in the unit
rates of contract for excavation items.
G) OVER EXCAVATION:
All possible precautions shall be taken to preserve the rock laying outside the
excavation lines in undisturbed and best possible conditions. Blasting shall be made
according to a pattern approved by the Engineer-in-charge. The amount and quality
of explosives and the sequence of detonation which shall diminish over break to the
minimum shall be used. The contractor shall take care to prevent over excavation
beyond the maximum excavation lines shown on the drawings taking all necessary
precautions regarding the spacing and distribution of drill holes, explosive quantities
245
and proper sequence of detonation. The contractor shall submit the scheme of
blasting for the approval of the Engineer-in-charge. The approval of the blasting
systems shall not in any way relieve the contractor from his obligations or diminish
his responsibilities towards obtaining smooth periphery and unshattered rock mass
around the excavations. If the system adopted by the contractor causes over breakage
outside the allowable limits, the Engineer-in-charge may order a change of the
system as deemed necessary and the contractor shall not claim any compensation in
addition to the payment for the excavation in accordance with the contract prices.
H) EXCAVATION OF TUNNELS THROUGH ROCK NOT REQUIRING

ANY PERMANENT STEEL SUPPORTS:
The contractor may execute the tunnel excavation by means of an appropriate
method approved by the Engineer-in-charge. He shall deploy such methodology and
equipment including the requisite job facility equipment, which could ensure safe
and efficient handling of all operations constituting the work cycle (listed below) for
completing the job within the provisions of this contract:
• drilling,
• charging and detonating,
• ventilation,
• scaling,
• loading and transport,
• Shotcreting or Guniting or/and rock bolting where necessary,
• erecting permanent support,
• installation of laggings backfill concreting behind steel supports, and
• setting out for the next round of blast.
I) ACTION PLAN:
Before initiating the tunnel excavation the contractor shall furnish to the Engineer,
his overall action plan, duly backed up with details of his construction equipment
planning and pro-posed envelopment along with a broad analysis of sequencing of
respective operations and their time and motion study. The rock drills/jack hammers,
shall be capable of giving high penetration rates in drilling. Suitable movable jumbos
shall be provided to facilitate drilling, loading, fixing of rock bolts and other
operations involved in excavation of the work. Full details of such jumbos shall be
furnished to Engineer-in-charge along with action plan.
J) DRILLING:
Efficient work cycle shall call for better work and better precision in different
operations of the work cycle from the contractor. It is of utmost importance that the
holes are drilled and at right locations and with right precision and that marking of
holes, viz. roof holes, wall holes and floor holes shall be angled out of the contour
that is "look-out" for the drilling equipment for the coming round. It shall not
normally exceed: 10 cm + 3 cm/m hole depth.
K) SMOOTH / CONTROLLED PERIMETER BLASTING:
The contractor shall evolve a smooth blasting or controlled contour blasting tech-
nique for tunneling as against normal profile blasting (where no consideration is
given to the appearance and condition of the blasted contour). Smooth blasting
technique shall be developed by him through a series of trial blasting aiming at
obtaining a smoother and stronger tunnel profile.
Smooth blasting will require closely spaced perimeter holes with an adjacent inner
row of holes, to be charged and fired together with the rest of the round. Not only
246
the perimeter/contour holes shall have light charges but the row of holes directly
next to them shall also be charged with well balanced charges since the excessive
charge in this row may break and rock beyond the intended rock excavation line
before the perimeter holes are blasted thereby skipping the final contour. Well
balanced charges in the holes next to the perimeter holes shall be used for achieving
the best results and avoid damage to the remaining rock beyond the perimeter holes.
Suitable drilling and loading pattern shall be furnished by contractor to Engineer's
representative before start of excavation work and subsequently when the contractor
proposes to change the pattern.
The cross section of the tunnel is divided into floor holes, wall holes and roof holes.
The floor holes shall before heavily charged than the stopping holes to compensate
for gravity and for the weight rock masses from the rest of the round which lay over
them at the instant of detonation. In firing sequence, these holes shall be ignited
earlier than the contour holes.
The contour holes as well as the holes in the row immediately adjacent to them shall
be charged with weaker explosives. However if such explosives are not used suitable
spacers of 30 cm length shall be used in between the explosives cartridges to achieve
the desired objective in both the contour holes and the row of holes immediately
next to them.
The firing pattern shall be so designed that the angle of breakage is as wide as
possible (close to 90 digress) Maximum number of both short (Millisecond) and
along (half second) delays shall be used into the round in order to reduce the
cooperating charges in the context of the fact that the blast-in-induced peak particle
velocity (PPV) is proportional to the quantum of co-operating charge. IF v-cut is
used, the angle of cut in the V's shall not be too acute and preferably not less than
60 degrees. More acute angles shall require higher charge concentration in the holes
which is not desirable. The delays shall be used to fire the V cut.
In the event of a tunnel passing through a bad zone on one side of its crown, that the
spacing holes on that side shall be made closer (reduced to half and alternate holes
shall be kept empty Depending on the nature of rock actually met with on side the
contractor may require to modify the drilling pattern, diameter of holes, spacing and
burden of holes, charge concentration ignition pattern and any other relevant
parameter through various trial blasts in order to evolve the best possible pattern and
submit such pattern, for final approval of the Engineer's representative.
L) GROUND VIBRATIONS:
The first few rounds blasted at the work-site shall be considered as test/trial blasting
and vibrations measurements shall be meticulously taken through deployment of
suitable vibration monitoring equipment for measuring the peak particle velocity
(PPV), frequency and acceleration as the particle velocity of the ground vibrations
constitutes the best parameter assessing the least criterion for damage. Control of
peak particle velocity is therefore most important. The results from the vibration
measurements obtained during the trial blasting operations shall be-utilised to find
the most economic and efficient drilling and firing pattern, consistent with limiting
the peak particles velocity (ppv) within permissible range. However, a certain
margin to the permitted vibration velocity shall be maintained as the ground
vibration may increase sharply if the blast does not go according to the plan, through
trial blasting and vibration measurements. The value of the important variable K
shall be determined from the following equation.
247
V= K (0.5 Q)1.7
D
Where, V = peak particle velocity in mm/sec.
Q = cooperating charge in kg.
D = distance from the blasting zone in m and
K = transmission factor constant, depending upon the rock characteristics
homogeneity of rock and presence of faults and cracks etc.
Efforts are being made to establish the value of 'K' the transmission factor constant
in respect of rock likely to be met within various elements of the contract works and
these values will be intimated to contractor in due course. Contractor has to adjust
type and' quantity of explosive that he has to use to keep the peak particle velocity
(PPV) within the permissible limits prescribed hereunder. All suitable help in taking
trial/test blast by Engineer-in-charge shall be given by the contractor as and when
demanded by Engineer-in-charge.
Broadly a peak particle velocity range of 70-100 mm/sec shall be the highest
permissible in good rock excavation and in this context, if two tunnels have to be
excavated simultaneously, the heading in one tunnel shall be kept at least 20 m
behind the other tunnel. However, if blasting is to be done in the vicinity of risk-
features, the permissible ppv shall be substantially reduced and the Engineer-in-
charge shall lay down the safe limit of ppvs. For sturdy concrete structures, ppv up
to 150 mm/sec, shall be permissible. Following ppv limits shall be adopted in respect
of concrete placement:
Time after concrete placement Permissible maximum

PPv
0 to 5 hrs No vibration restriction
5 hrs to 4 days 30mm/sec
5 to 11days 50mm/sec
12 to 28 days 70 mm/sec
>28 days /sec
Having determined “K” from the above equation for different blasting sites (work
headings) the explosive charge (co-operating charge) shall be controlled through
appropriate ignition pattern in the blasting round to keep the desired feature/structure
within the permissible ppv limit.
4.1.5 Mode of Measurement:-
(1) The quantity for underground excavation shall be in cubic meter of in-situ rock
for each rock class excavated within Line 3 (payment line) as shown in Figure 3.1
and/or as directed by the ENGINEER as herein before prescribed and accepted with
all its additional requirements. The quantity for the Over break in case decided by
the ENGINEER as unavoidable shall be measured beyond the pay line (P-line or
Line 3) as shown on the drawings and in Fig 3.1 above. For the portion of the
unavoidable over break that exceeds beyond the pay line (P-line or Line 3) and
exceeds 2 m³ in volume in each case, separate remuneration shall be made at 50%
of the applicable Unit Rate for excavation quoted in the Bill of Quantities. The cavity
or void formed by the over break shall be measured in-situ and shall be quantified
and approved by the ENGINEER and certified for payment. The CONTRACTOR
248
shall have no right to claim for additional payment due to increment of quantity for
correcting errors of setting-out incurred from his fault.
2) Before commencing excavation of a round and after completion of the round, the
CONTRACTOR shall take survey measurements sufficient to define the excavation
cross-section dimensions and elevation of the original surfaces and elevation
surfaces of rock excavation. This shall be subject to the ENGINEER’s approval prior
to adopting in force.
3) Additional costs for tunnel excavation due to water inflow exceeding 50 LPS in
upward and downward drives shall be compensated for by separate items as shown
in the Bill of Quantities, independent of the encountered rock class. In upward tunnel
drives, the measurement of the water inflow shall be carried out 25 m behind the
tunnel face. In downward tunnel drives, measurement shall be performed for the
water inflow occurring within the last 5 m behind the tunnel face. For water inflows
up to 50 LPS in upward and downward drives there shall be no separate payment.
The costs shall be included in the Unit Rates for excavation.
4) Costs for required re-profiling works shall be compensated for only where actual
(i.e. measured) deformations of the primary shotcrete lining have exceeded
deformation tolerances as instructed by the ENGINEER. The Unit Rates quoted in
the Bill of Quantities shall include excavation, transportation up to 1.5 km from
tunnel portal / shaft head and disposal of excavation material and support elements.
5) The quantity for excavation of tunnel niches shall be in cubic meter of in-situ
rock. The payment shall be on one unit rate only as per the BOQ item for the same,
irrespective of the rock class excavated. The specifications of Clause (1) above shall
apply. No separate payment shall be made for the removal of already installed tunnel
support. These costs shall be included in the Unit Rates for excavation.
6) No separate remuneration shall be paid for the demolition of shotcrete linings at
the tunnel face at portal slopes. These costs shall be included in the Unit Rates for
excavation.
7) No separate remuneration shall be paid for the removal of temporary support
installed at the tunnel face or at the top heading invert. These costs shall be included
in the Unit Rates for excavation.
8) No separate remuneration shall be paid for geological mapping during tunnel
Excavation. These costs shall be included in the Unit Rates for excavation.
9) Where fore poling is required, no separate remuneration for the additional over
break will be made, i.e. the additional over break shall be included in the excavation
costs.
10) No separate compensation for the provisions for the start of tunnel excavation
from the pre-cut is envisaged. The quoted rate for underground excavation shall
include all costs required for the construction of the canopy structure (false portal).
11) No separate remuneration is admissible for transport of excavation material up
to a distance of 1.5 km from the tunnel portal / shaft head and for disposal and
compaction of the excavation material at the disposal site as all transportation and
disposal costs shall be included in the excavation costs. For transportation of
excavated material for a distance exceeding 1.5 km and upto 10 km from the tunnel
portal / shaft head, separate payment will be made.
12) All work involved with and any partial or short interruptions or inconveniences
caused by the check surveys, installation of instruments and performance of
monitoring, performance of the rock mechanics tests and geological mapping, for
which no separate payment is provided elsewhere in these specifications.
249
13) The supply of geotechnical instrumentation, the installation of the instruments
(except for the convergence bolts in the tunnel and the settlement markers at portals)
and the taking of readings will be part of a separate contract under KRCL. However,
the CONTRACTOR shall provide all auxiliary works and equipment required for
geotechnical monitoring, e.g. staff for assistance in installation of the instruments,
drilling of boreholes, grouting, mortars and other accessories, lighting, lifting
equipment, as well as the installation of the convergence bolts as instructed by the
ENGINEER, etc. Except for the drilling work for extensometer and piezometer
installation all these auxiliary works will not be reimbursed separately and the costs
for these items shall be included in the Unit Rates for excavation.
14)The Contractor shall be responsible and shall coordinate with the Monitoring
Contractor for proper protection of installed instruments.
15)The Contractor shall provide immediate replacement of instruments, which are
damaged by construction activities at his cost.
16)Upon completion of the work, the Engineer-in-charge will either order plugging
of such tunnels with concrete at the contractor’s cost or he may adopt them for a
particular use by affecting required protections and modifications. The payment for
such protection and / or modification work
ordered by the Engineer-in-charge shall only be made according to the applicable
contract rates for the ordered work.
The excavation shall not however be payable on any account. The construction of
such auxiliary tunnels shall meet the requirements stipulated in these sections of
technical specifications and shall be under the supervision and approval of the
Engineer-in-charge.

1) The quantities determined as provided above shall be paid for at the contract Unit
Rates respectively for each of the particular pay items shown in the Bill of Quantities,
which price and payment shall be full compensation for all the costs of labour,
supervisors, materials, the CONTRACTOR’s equipment, auxiliary facilities, draining
and all other work necessary in the proper completion of the work prescribed in this
Section.
(2) Payment shall be made for excavation within the payment line (Fig. 3.1). No
payment shall be made for over break which in the opinion of the ENGINEER is
considered as avoidable. In case of unavoidable over break, payment shall be made at
50% of the rate as given in the Bill of Quantities based on measurement as stated
above. Reimbursement for excavation will exclusively be based on the rock class as
determined for the top heading. For bench and invert the same unit rates per cubic
meter as for the top heading shall apply. Support measures shall not be criterion for
excavation reimbursement.
250
General specifications:
Apart from what has been stipulated above, the excavation shall be
carried out in accordance with the relevant provisions of following Indian
Standard specifications and to the dimensions lines and grades shown in the
contract drawings.
i. Code of Practice for construction of Tunnels ( Part I) precision survey and
setting out IS 5878 ( Part I) 1971
ii. Code of practice for construction of Tunnels ( Part II) underground
excavation in rock section I drilling and blasting- IS 5878 ( Part II / Section I)
1970 & IS 4081-1986.
iii. Code of practice for construction of tunnels ( Part II) underground
excavation in rock section 2 : Ventilation, lighting, mucking and dewatering –
IS5878 ( Part II, Section -2) 1971
iv. Code of practice for construction of tunnels Part II underground
excavation in rock Section 3. Tunneling methods of steadily inclined tunnels,
shafts and underground Power House IS-5878 (Part II /Section 3) 1971.
v. Code of practice for construction of tunnels ( part IV) Tunnel supports IS
5878 ( Part 4th ) 1971.
NOTE: For Lighting and Ventilation, Safety Precautions & Drainage Refer
Specifications Miscellaneous item.
251
4.2 Providing and fixing steel rock bolts. (Item No. TN04 A & TN04 B)
Providing and fixing steel rock bolts of 25 mm diameter and 3.10 m length with
resin bond cement capsule anchorage through adit / itself & shaft including drilling
holes, inserting grout capsule, driving bolt, fixing 10 mm thick plate and nuts and
tightening the same by torque wrench after hardening of cement grout, cost of all
materials, machinery, labour, ventilation, lighting, drainage and other ancillary
operations etc complete with lead upto 1.5 km and all lifts.
Total weight of rock bolt 3.10 x 3.85 x 10 = 122.33 kg
4.2.2 Scope of work

The contractor shall ensure that all components of the rock bolts including the bolt
bar, expansion anchors, washers, nuts, bearing plates, plug etc. shall confirm to the
specifications prescribed by the Engineer-in-charge. The contractor shall install the
rock bolts according to the instructions of the Engineer-in-charge. The contractor
shall also perform pull out tests as specified and desired by the Engineer-in-charge.
The systematic pre-stressed rock bolts system shall be covered with layers of
shotcrete reinforced with wire mesh, wherever prescribed by the Engineer-in-
charge. The wire mesh and the shotcrete shall follow the specifications prescribed
by the Engineer-in-charge.
The rock bolts may be of the following types:
• Mechanically anchored mortar grouted rock bolts, (mainly used for spot bolting)
• Mechanically anchored tensioned rock bolts.(which may be grouted after
tensioning)
• Resin anchored mortar grouted rock bolts.
• Resin anchored resin grouted rock bolts.
The rock bolts shall be made of high strength steel deformed bars (tor steel)
confirming to “cold worked steel High Strength Deformed bars concrete
Reinforcement” IS 1786-2008 or its subsequent revision.
The length of the rock bolts, their pattern and the pre-tension shall be as shown in
the drawings or as prescribed by the Engineer-in-charge. Rock bolts shall have a
tensile strength in the range of 5500 to 6000 kg/cm2 and a minimum yield point of
4950 kg/cm2and minimum elongation of 14.5 percent and these shall be threaded
with rolled threads at-least 200 mm in length at both ends.
4.2.3. A) Testing
• Grout Mortar
(1) Prior to acceptance tests of rock bolts, tests with available cements and sands
shall be carried out to determine an appropriate mix design to achieve the specified
strength and a proper workability in association with the grouting equipment used.
(2) Additives may be used to improve workability. The influence of the additive to
the strength development shall be followed by tests as described under this Clause.
252
(3) The grout mortar shall be tested on cubes 5x5x5 cm. The cubes shall be cured in
water.
(4) Five numbers of cubes shall be prepared for each compressive strength test. The
resultant strength is the average evaluated from the three remaining values after
elimination of the highest and the lowest.
(5) During construction, cube sample shall be taken weekly at each five bolts drivage
from the grouting hose at the nozzle. Preparation and evaluation shall follow the
procedure as described above.
• Pull Out Tests on Rock Bolts
Pull-out tests shall be performed on basis of ISRM Doc.2, Part 1 "Suggested Method
for Rock bolt Testing".
(1) Proof Tests
(i) A detailed test program set up on basis of above mentioned document shall be
approved by the engineer prior to all testing work.
(ii) Specifically deviations from the ISRM suggested method shall be approved by
the engineer.
(iii) A test report shall be issued immediately after completion of the tests. It shall
be submitted for approval to the engineer.
(iv) For each type of rock bolt submitted information shall comprise:
a. type of bolts
b. testing equipment
c. location and installation records
d. applied testing loads and records of deformation
e. otherwise the evaluation of test results as specified in ISRM's
document
f. interpretation and suggested action for failed pull-out tests
(v) Proof tests shall be carried out for all types of bolts to be used for this project
prior to the commencement of tunneling to demonstrate the effect and the service
capacity of the bolts in the field.
(vi) The tests shall be performed in similar geological ground conditions as expected
during tunnel drivage. The location of the bolts to be tested shall be selected by the
engineer.
(vii) A minimum of five bolts of each type shall be tested. Depending on the testing
procedure and the test results the engineer may require further bolts to be tested.
(viii) Adequate testing equipment, as specified in the above mentioned ISRM
document shall be provided to record bolt elongation, movement of the bolts and
tension forces.
(ix) The maximum load to be applied shall be the bolt´s yield load or as otherwise
approved by the engineer.
(2) Testing during Tunnel Driving. The engineer will select rock bolts for testing of
production bolts. For each type of rock bolts five bolts will be selected from the first
100 bolts placed in the tunnel. From the remaining bolts five per 500 bolts will be
selected for testing purpose. The testing force to be applied shall be equal to 80% of
the bolt´s yield load.
(i) Bolts which fail the tests or which are pulled out shall be replaced.
(ii) For each failure, the engineer shall require further bolts to be tested in the
vicinity.
(iii) Otherwise as Clause (i) to (ix) in (1) above.
253
4.2.4. Sequence of Execution
The contractor shall drill holes of dia. suitable to the above mentioned dia. Of bolts
in the roof or on the sides of the excavated portion of the tunnel at the location
specified by the representative of the Engineer-in-charge. Depth and directions of
each rock bolt shall also be got approved by the Engineer-in-charge.
The location, depth and direction of each rock bolt would vary in different situation
depending upon geological nature of rock met with.

The quantities of rock bolts to be paid for shall be the number of various types and
lengths of rock bolts as shown on the drawings and/or directed by the engineer as
herein before described and accepted with all its additional requirements.

The accepted quantity measured as provided above shall be paid for at the contract
unit prices respectively for the pay items shown in the Bill of Quantities which price
and payment shall be full compensation for all labour, supervisors, materials, the
contractor’s equipment, drilling, installation, grouting and testing for rock bolts or
any other contingencies. No payment shall be made for unqualified rock bolts.
NOTE: For Lighting and Ventilation Refer Specifications for Miscellaneous item.
254
4.3. Providing and fixing anchor bars (Item No.TN05A, TN05B &
TN06A, TN06B.)
Providing and fixing anchor bar of 25 mm diameter 3.375 m / 32 mm diameter
4.32 m with resin bond cement capsule anchorage through adit / itself & shaft
including drilling holes, inserting grout capsule, driving anchor, cost of all materials,
machinery, labour, ventilation, lighting, drainage and other ancillary operations etc
complete with lead upto 1.5 km and all lifts.
Total weight of 25 mm steel 3.375 x 3.85 x 10 = 133.19 kg / Total weight of 32 mm
steel 4.32 x 6.32 x 10 = 279.85 kg
4.3.2 Scope of work
Where indicated on the drawings or directed by the Engineer-in-charge, holes shall
be drilled into rock to receive bars for anchoring to the rock ,concrete or masonry
structures or parts thereof. The type & dimensions of the anchor bars, location
diameter and depths of anchor bar holes shall be as shown on the drawings as
directed. The diameter of each anchor bar hole shall be as of required i.e. a hole
drilled by an ordinary jack hammer used for excavation etc.
The type and dimensions of the anchor bars, locations diameters and depths of
anchor bar holes shall be as directed by the Engineer-in-charge. The hole shall be
drilled into rock to receive 25mm/ 32mm dia. Steel bars for anchoring as directed
by the Engineer-in-Charge. The number of anchor bars required per bay shall be
decided by the Engineer-in-Charge The diameter of each anchor bar hole shall be
specified. The cement grout shall be of proportion 1:3 (Cement. Sand) and of desired
consistency.
Wherever shown on Drawings or directed by the Engineer in charge holes

shall be drilled into the rock to receive bars for anchoring. The diameter of holes
shall not be less than 1½ times the diameter of the anchor bars specified. Anchor
bars shall be thoroughly cleaned before being placed in the drill hole. All the water
shall be removed from the holes before placing the anchor grout.
Either cement slurry or cement mortar/cement capsules shall be used for grouting of
anchors as may be directed by the Engineer-in-charge.
The anchor bars shall be forced into place before the grouting or mortar has taken
its initial set and where practicable, shall be vibrated or rammed until the entire
surface of the embedded portion of the bars is intimated contact with the grout.
Anchor bars shall be placed sufficiently in advance of concrete operations to allow
the grout to set.
The anchor fixed in position properly to the specified length, special care shall be
taken to prevent any movement of bars after the grout and mortar have taken the
initial set.
255
Measurement for drilling holes for anchor bars and grouting bars in place will be
based upon the length of holes required to be drilled and grouted beyond the surface
of the rock excavation. The rates quoted in the schedule of prices shall be for this
diameter of anchor bar per number the holes.

1) Anchor bars found loose after setting shall be replaced by others at the expenses
of the contractor.
2)Payment for anchors will be made on the basis of number of anchor bars used, The
cost of mortar or cement slurry used for fixing the anchor rod in position shall be
covered by the rate of the item for reinforcement.
3) Payment for fixing of anchor bars, grouting, bars in place shall be deemed to be
included in the unit rate provided for the item in the schedule of bids which unit rate
shall also include the cost of cutting and being of anchor bars, furnishing grout,
drilling holes and grouting the bars in place, including of cleaning of steel bars
compacting grout and all T & P and labour for all operation etc..
----------***----------
256
4.4 Providing, fabricating and fixing in position permanent structural
steel supports. ( Item No. TN 07A & TN 07B)

Providing, fabricating and fixing in position permanent structural steel supports
through adit / itself & shaft as per details including cost of all materials, machinery,
labour, cutting, bending, welding, grinding, lighting, ventilation, drainage and all
other ancillary operations etc complete with lead upto 1.5 km and all lifts.
4.4.2 Scope of work
For the purpose of these specifications, permanent supports in the form of structural
steel member are defined as the steel supports, which shall be left in place and be
embedded in the concrete lining and shall include the structural steel supports,
complete with all rivets, welds, bolts, nuts, spikes, dowels, wedges, tie rods,
wrenches or other accessories required for assembling the supports, erecting and
supporting them in place until the concrete lining is placed.
Structural steel for support shall as per IS 226 (1975) & 2062(1992)
Permanent structural steel supports: Suitable permanent structural steel

supports, as specified herein, shall be used to support the roof and sides of the tunnel
when required and approved by the Engineer in charge. Immediately after
completing the excavation of a specified length of the tunnel, suitable anchors shall
be provided with side / roof for supporting the permanent supports where necessary
and directed. The space between permanent support and the excavated surfaces shall
be filled with concrete / shotcrete. The contractor shall fabricate steel structural ribs,
wall plates, foot beams, foot plates, liner plates and other approved structural rivets,
bolts, nuts, wedges, spikes, drift pins, dowels, tie rods and other accessories required
for fabrication, welding of supports, erecting and holding them in place and all
temporary timber spreaders when required. The permanent steel supports, as are
approved by Engineer in-charge shall be placed in an approved manner true to
established lines, grades, and dimensions and shall be maintained by the contractor
in proper condition and alignment until the concrete lining has been placed. The
distance between structural steel ribs supports shall be as shown on Drawings or as
directed by the Engineer in charge. Ribs shall be secured against movement or
distortion by steel tie members and compression struts under certain rock condition
the loads and side pressure may be increase due to gradual subsidence of rock and if
supports initially provided are found in adequate sequently due to such increase in
load to an extent more than provided for initially, the contractor shall take
appropriate measures at appropriate time, strength the supports and pack the material
behind the supports or any other measures as approved by the Engineer in charge
and shall be paid for at the unit price provided in schedule of quantities and prices.
The temporary timber spreads shall be furnished and installed by the contractor
where required and shall be removed before placement of lining. The contractor shall
not be entitled to any payment for furnishing and placing of temporary timber
supports or spreaders and removing the same before lining. Thus additional
257
permanent supports or other than those shown on tender drawings may also be
required to be used as directed by the Engineer in charge from time to time. The
quantity shown in schedule of quantities for this item is tentative and the quantity,
size and spacing of permanent supports may vary. The contractor shall carry out the
work as actually required at site and he shall not be entitled to any additional
allowance over and above the schedule of quantities and prices on account of any
variation in size, spacing and other parameters of permanent supports. Any required
repair to or, replacement of support due to contractors operation and negligence shall
be made by and at the expenses of the contractor.

The contract rate for permanent supports shall be for one metric tonne of structural
steel provided, fabricated, completed and set out in correct position on site as per
drawing or as approved by the Engineer-in-charge. Measurement of this item shall
be in metric tonne and rounded upto two decimals.
In the case of rolled sections, length shall be measured correct to a cm. and weight
calculated on the standard weight per meter tabulated in the ISI Hand Book for
structural steel sections limited to the length shown on the plans correct upto 0.10 of
kg. Weight of steel plates of each thickness shall be calculated separately on the
basis of actual shape provided without taking into account wastage. In case of bolted
work, weight of bolts,nuts and washers shall be added in full and no deduction shall
be made for bolt holes. In riveted work only the weight of rivet heads shall be added.
No deduction shall be made for rivet holes. No increase in weight shall be allowed
in welded work due to welding.

The payment for fabrication and erection of permanent steel supports will be made
for the quantity of permanent steel supports at unit price per metric tones provided
there for in schedule of quantities and prices. The unit price shall be deemed to be
included cost of furnishing and carriage of all labour, tools, plants and equipment,
materials consumables, and all that is necessary for fabricating, handling into
position and erection of permanent steel supports. Including ventilation and lighting
of work area in accordance with the specifications laid down. The unit price shall
also be deemed to include cost of cutting holes for bolts and rivets and cost of
furnishing and fixing such bolts, rivets, nuts and washers complete cost of all
welding required including all materials required there for shall also be deemed to
be included in the unit price.
----------***----------
258
4.5 Providing, fabricating and placing in position reinforcement steel for
tunnel RCC works.( Item No. TN 08A & TN 08B)

Providing, fabricating and placing in position reinforcement steel for tunnel
RCC works through adit / itself & shaft including cleaning, straightening, cutting,
bending, hooking, lapping, welding joints wherever required tying with binding wire
including cost of all materials, machinery, labour, lighting, ventilation, drainage etc.
complete with initial lead upto 1.5 km and all lifts.
4.5.2 Scope of work

The contractor shall make arrangements for handling, transporting
steel to site of works and for cutting, bending and placing reinforcement as indicated
on construction Drawings or as directed by the Engineer in charge and include all
the charges in unit rates.
Steel reinforcement shall be tor steel or as specified or as directed by the Engineer

in charge and shall conform to relevant IS specification cold twisted steel bars shall
comply with the requirements of I. S. 280 of 2006 as revised from time to time. Wire
for tying reinforcement shall be of soft and unsealed steel and shall be conformed to
IS 280 (2006). Reinforcement bars shall be properly stored and stacked on wooden
skids to prevent the steel from coming into contact with soil. Bars of the same size,
length, shape and grade shall be assembled in racks / stacks and marked distinctly.
Drawings :
Detailed bar lists and bar bending diagrams showing the number, size, length and
bending of all bars required in various parts of the work shall prepared by the
contractor. Such bar schedule shall be submitted to the Engineer in charge for
checking well before their requirement for placement.
A)Cutting, bending, binding and placing reinforcement:

Reinforcement bars shall be of sizes prescribed and shall be cut to the requirements
up to shapes and fixed in position as shown on Drawings or as directed by the
Engineer in charge. Cutting, bending, binding and placing reinforcement shall
conform to IS specifications IS 2502 of 1963 as revised from time to time.
Reinforcement shall not be straightened or bent in a manner that will inure or weaken
the material. Bars shall be bent cold to the shape and dimensions required. Heating
of bars for bending shall not be allowed except where specifically permitted by the
Engineer in charge. Deformed bars shall not be re-bent after being bent and
straightened unless initial bending and subsequent straightening and bending and all
carried out with the bar heated to cherry red heat and all operations are carried out
under proper supervision. Bars bent hot shall not be cooled by quenching. Before
placing the reinforcement bars in position all bars shall be thoroughly cleaned of all
loose rust, oil, scale, grease and other foreign substance and care shall be taken to
keep them in this condition until concrete is placed. All bars shall be of size and
length directed and no substitution shall be made unless approved in writing by the
Engineer in charge. Splices of reinforcement shall not be made at points of high
259
bending moment except as specifically approved. Spliced bars shall provide
sufficient lap to transfer stresses by bond only. Reinforcement shall be placed
accurately in position shown on Drawing sand shall be held firmly in position during
placing and setting of the concrete. The reinforcement shall be maintained in
position by use of built in concrete blocks, steel chairs, steel spacers, steel hangers,
and other steel supports as approved by Engineer in charge at sufficiently close
intervals, so that they will not sag between supports or be displaced during the
placing of concrete. Where reinforcement bars intersect they shall be securely
connected with tying binding wires as per IS specifications. Tying wires and steel
supports shall not be carried to permanently exposed surfaces and shall be subject to
the same requirements as reinforced steel with regard to concrete cover. Whenever
possible the contractor shall remove the spacer blocks, provided their removal does
not disturb the concrete. Exposed reinforcement intended for binding or dowelling
between two placement of concrete shall be protected from being disturbed and shall
be thoroughly cleaned prior to subsequent concreting. Reinforcement shall be so
placed that there will be a clear distance between the reinforcement shall be as per
IS 456 (2000) and any anchor bolts or embedded metal work, except as otherwise
directed by the Engineer in-charge. Reinforcement shall be covered with the
concrete to the minimum depths shown on Drawings. The similar portals shall not
be placed intimate proximity with each other nor be joined by conductor especially
in the continued presence of moisture, unless it is known that no galvanic action will
result. (The relative galvanic action in the electrometers series). Tack welding of
bars may also be permitted to keep the bars in position. Such tacking should not
cause cutting of the bars.
B) Jointing and splicing:

Joint or splices in reinforcement bars shall be made at locations shown on the
Drawings or as directed by the Engineer in charge and shall not ordinarily be closer
than 6 meters. Additional joints or splices may be permitted at positions other than
those shown on the Drawings, provided position of joints in adjacent bars is
staggered as approved by Engineer-In-Charge. The reinforcement shall be so placed
that the joints in reinforcement bars are staggered by at least 50%. Splicing shall be
done either by providing overlap to transfer stresses by bond or by welding as per
standard practices or as approved by the Engineer in charge. No lapping or splicing
shall be made at the points of high bending moments. Reinforcement bars of 25 mm
diameter and less shall normally be provided with standard overlap. Reinforcement
bars of 28 mm diameter and above shall be butt welded with overlap angle in
accordance with provisions of I.S.2751 of 1979 or latest revision thereof. Weld
splicing may also be permitted with overlap. The butt welding / lap / splice welding
shall be in accordance with Indian Standard specifications. Welding of
reinforcement bars shall be performed under cover from the weather and shall be
performed by the electric method, using suitable electrodes which shall be got
approved by the Engineer in-charge. In case of welding done to join bars of different
sizes, the length of lap shall be governed by the smaller size bars and payments made
for the same. All welding shall be one in accordance with provisions of IS 816 of
1969 as revised from time to time. Welding materials, welding procedures and
workmanship of welders etc. will be subject to inspection and approval at all times
during the progress of the work. The specimens for different types of welded splices
and for different sizes of bars shall be required to be prepared by the contractor free
260
of cost for ascertaining the quality of welders and welding. Samples shall be got
tested by the project at contractors cost.

Measurement of steel reinforcement shall be made to arrive at the Weight of steel
reinforcement by linear measurements (Exclusive of the weight of weld splices and
binding wire) actually placed in position and embedded in concrete in accordance
with the approved drawings. Steel used for lap pages as per instructions of Engineer
in charge and as authorized by him will be considered as bonafide use and included
in measurement. However binding wire pins, chairs, tie rods, spacers, supports used
for keeping reinforcement in position, line and grade shall not be included in
measurement for payment.

Payment shall be made at the unit rate provided there for in the “Schedule of
quantities and prices” reinforcement shall include the cost of transportation of steel
from project stores to site of work, its storage at site, the cost of supplying,
fabricating, binding wire, chairs, pins, spacers, ties and metal supports, if any,
hauling, sorting, straightening, cutting bending, cleaning, placing ,securing and
maintaining in position all reinforcement bars as shown on Drawings or as directed
by the Engineer in charge and plant and materials required for carrying out all
operations under the specification excluding cost of reinforcement steel.
----------***----------
261
4.6 Providing and applying wet shotcrete (Item No. TN 09(A) & TN 09(B))
Providing and applying wet shotcrete (M-30: 10MSA) 50 mm thick in two layers
through adit / itself & shaft of tunnel including admixtures, neccessary machinery,
labours, scaffolding, lighting, drainage, ventilation with providing and all other
ancillary operations etc., complete with lead upto 1.5 km and all lifts.(Excluding
Royalty)
4.6.2 Scope of work

Shotcrete shall confirm to relevant provisions contained in technical specification of
concrete lining. Where the tunnels or other excavation passes through loose or soft
rock which are liable to disintegrate on exposure to air or to become loose or unstable
due to running water or other causes, immediate shotcreting must be carried out and
if very unstable strata is met with immediate steel supporting shall be carried out as
per the directions of the Engineer-in-charge.
1. GENERAL
i) In the roof and walls of the caverns, Tail surge, intake structure, etc. and other
places where specified on the drawing or as directed by the Engineer-in-charge, it
will be necessary to treat rock surface by means of shotcreting and to strengthening
the rock mass by rock bolts.Further additional supporting layer of shotcrete with
welded wire mesh reinforcement shall be applied wherever necessary. This part of
the specification deals with for the material and placing of shotcrete with or without
welded wire mesh reinforcement except when they are not in accordance with the
condition given in the paragraph hereafter. The pertinent requirements not included
in the specifications, shall be followed as per the IS 9012-1987 or its subsequent
revision ‘Recommended practice for shotcreting”.
2. SAND
II) Sand must be well graded and with gradation according to the requirements of
concrete specified in this Para and in conformity with the provisions contained in IS
9012-1987 or its subsequent revision. If the sand has a fines deficiency,
diatomaceous earth can be added with the previous approval of the Engineer-in-
charge, up to 3% of the cement weight of the mix to increase the plasticity and
decrease mix-rebound.
3. COARSE AGGREGATE.
III) Coarse aggregate shall also comply the requirement as specified in IS 9012-1987
“Recommended practice for shotcrete”. It shall generally confirm one of the grading
given in table below:
262
GRADING OF COARSE AGGREGAES.
IS Sieve Percentage by Mass passing for Aggregate of Nominal Maximum
Designation 10mm 12.5mm 20mm
1 2 3 4
mm
25 - - 100
20 - 100 90-100
12.5 100 90-100 -
10 85-100 40-70 20-55
4.75 10-30 0-15 0-10
2.36 0-10 0-5 0-5
1.18 0-5 - -
4.WATER:
Water used for shotcrete shall confirm the requirements of IS-456-2000.

5.Admixture.
Admixture when used shall meet the requirements of IS 456-1978 and IS 9103-1979
(specification for admixture; for concrete). For the shotcrete manufacturing, it might
be necessary to use additives to produce entrained air, to prevent cracks or for setting
acceleration. The admixture to be used shall be got approved from the Engineer-in-
charge before use in the work. Exact amount to be used shall be determined at the
time of construction. Cost of admixture, its handling etc. is deemed to be including
in the unit rate of the item of shotcreting.
6. CEMENT
All types of cement used for regular concrete shall normally be suitable for shotcrete.
For high casting strength, rapid hardening port-land cement should be preferred.
7. PROPORTIONING OF SHOTCRETE.
The mix proportions and the quantity of water to be used shall be determined and
adjusted at the work-site in order to obtain shotcrete of optimum consistency. The
water cement ratio shall be between 0.35 and 0.5 by weight.
The compressive strength of shotcrete shall meet the following minimum strength
requirement.
263
After 2 hours 14.8kg/cm2
12 hours 56.2kg/cm2
24 hours 105.4kg/cm2
28 days 280kg/cm2
The flexural strength of test beams for shotcrete at 28 days shall not be less than
42.25kg/cm2. The shotcrete shall have cement, sand and coarse aggregates and water
in proportion of mix design by weight. The weight of each component shall be
decided by trial mixes in laboratory in order to obtain a dense mix with minimum
compressive strength as mentioned above. The fine and coarse aggregates shall be
thoroughly mixed in an approved mixer and with the cement and admixtures, if used
at the correct rate to achieve the required proportions and shall enter the shotcrete
machine in such a way as to achieve proper mixing. The shotcretes shall have a
minimum cement content of 400 kg/m3 as discharged from the nozzle and a
maximum water cement ratio of 0.5 by weight. The contractor shall provide for
sufficient over design strength to allow for variations in his workmanship and meet
the strength and other requirement during shotcrete application. Shotcrete will be
apply on the tunnel walls and roofs to the required thickness in one pass, unless
abnormal conditions are encountered. The dry mix shall be first prepared with
required moisture so as not to allow cement particles to fly in the atmosphere. The
additional water as required according to water cement ratio should be added at the
nozzle.Dry mixed ingredients which contain set accelerating admixtures shall be
discarded if they are not placed within 30 minutes or a time as determined by the
Engineer-in-charge depending on the moisture control of the mix and the amount of
admixture. Payment will not be made for such discarded material.
8. REINFORCEMENT FOR SHOTCRETE.

Reinforcement mesh to be used shall confirm to IS 9012-1987 or its latest edition.
Shotcrete shall be reinforcement with welded wire mesh 50mm x 50mm x5 mm
mesh or in its substitution with another type of mesh of best quality and
characteristics approved by the Engineer-in-charge. The supply of mesh shall be
done by the contractor and its placing shall meet the requirements of the
specifications. The mesh shall be placed as close to the rock as possible to prevent
the shotcrete jet producing undesirable vibration to the mesh.
Steel mesh support may be ordered to be fixed after the application of an initial
shotcrete layer. Prior to fixing the steel mesh support, the excavated surface shall
first be trimmed to the required lines and all loose rock, rock fragments and debris
removed where these would not normally be able to be removed from beyond the
mesh without disturbing the same. The steel mesh shall be secured to the excavation
face with holding points generally set at a maximum spacing of 0.5 m so as to draw
the mesh tightly against the excavation face. The holding points shall be positioned
so as to grip at least two separate strands of mesh at each anchorage point. When
used in conjunction with rock bolts the mesh shall be firmly bolted to the rock bolts
by means of the appropriate nuts and washers. The contractor shall ensure that the
ends of the anchors do not project to closer than 50 mm from the final lining face of
beyond the excavation clearance line by more than 70mm in the case of excavations
receiving only a nominal shotcrete or gunite lining.
264
Laps in steel mesh support shall be formed by lapping the mesh for a length of at
least 3 bar spaces; for welded mesh and 6 bar spaces for chain link or expanded metal
mesh and by inserting rock anchors at a spacing not exceeding 750mm along the
length of the lap. When used in conjunction with rock bolts, the lap shall be arranged
to coincide with the lines of rock bolts.
Where steel mesh is required to contain rock spoils and fragments, the rock anchors
shall be installed in a staggered pattern in order to provide maximum support to the
mesh. Anchors shall be inserted in areas of relatively sound and massive rock.
Testing
• Grout Mortar
(1) Prior to acceptance tests of rock bolts, tests with available cements and sands
shall be carried out to determine an appropriate mix design to achieve the specified
strength and a proper workability in association with the grouting equipment used.
(2) Additives may be used to improve workability. The influence of the additive to
the strength development shall be followed by tests as described under this Clause.
(3) The grout mortar shall be tested on cubes 5x5x5 cm. The cubes shall be cured in
water.
(4) Five numbers of cubes shall be prepared for each compressive strength test. The
resultant strength is the average evaluated from the three remaining values after
elimination of the highest and the lowest.
(5) During construction, cube sample shall be taken weekly at each five bolts drivage
from the grouting hose at the nozzle. Preparation and evaluation shall follow the
procedure as described above.
• EQUIPMENT AND WORKMANSHIP.
Not less than 30 days prior to applying any shotcrete, the contractor shall submit
drawings for approval showing his proposed plant arrangement together with a
general description of the equipment he proposes to use, the methods of operation
and the mix proportions and admixtures. Mixing of ingredients by hand will not be
allowed. The contractor shall employ only skilled nozzle man and before being
permitted to perform any production application of shotcrete, each nozzle man shall
demonstrate to the Engineer-in-charge his ability to apply shotcrete to the required
standard including regulation of the water cement ratio.
Air and water shall be provided in sufficient volume and under such pressure as may
be sufficient and necessary for the best operating conditions. In applying the
shotcrete, the discharge nozzle shall be held so that the stream of material shall
impinge as nearly as possible at the optimum angle to the surface for minimum
rebound, and the velocity of discharge from the nozzle the distance of the nozzle
from the surface and the amount of water used in the mix shall be regulated so as to
produce a coating with a minimum rebound of the materials and no sagging
obstruction such as service line shall be remolded to enable direct application of
shotcrete to the surfaces. Rebounding material shall not be used again but shall be
removed from the work and disposed off by the contractor as part of the work under
this clause. During the application of shotcrete the contractor shall provide adequate
ventilation facilities and take such other measures as are necessary for safety of his
workmen including provision of face protection for nozzle man.
All the machinery like air compressor, shotcrete machine pump etc. required for the
work of shotcrete lining and its connected work shall be brought, maintained an
operated by the contractor at his risk and cost. No separate payment for bringing
265
machinery and erecting it shall be made. Shifting of machinery at work-site shall be
done as directed by the Engineer-in-charge. No separate payment for shifting of
machineries and erecting it during execution of work shall be made.
• CURING.
Good curing is particularly very important for the very thin sections. Rough surfaces
and mixes of low workability normally associated with shotcrete. The shotcreted
surfaces shall be kept continuously wet at least for 7 days.
• GROUND VIBRATIONS.
A preliminary vibration limit of 150 mm/sec. as peak particle velocity (ppv) shall be
considered as permissible for shotcreting operation 10m from the blasting site. This
applies to shotcreting being used on a permanent support constituent for a distance
less than 10m from blasting zone, shotcrete shall be used only for temporary;
support.
• TESTS.
As specified in IS 9012-1987 “Recommended practice for shotcrete” before starting
the shotcrete placing, laboratory tests shall be made to check the equipment and
personnel in charge of this work and to verify the shotcrete ;quality that may be
obtained. The Engineer-in-charge shall determine whether the testing operations are
made either by means of panels built for this purpose as described in IS 9012-1987
Para-6 or by means of samples taken from the applied shotcrete in this work or if
any other one used for this purpose.
The acceptance criteria of test results shall be as per Para IS of IS 456-2000 “Code
of practice for plain and reinforced concrete.
Concrete cubes prepared by directly gunning into 15cm cube moulds may also be
used for day to day quality control test. In such cases, the results should be correlated
to the results from tests of cubes made from panels. Frequency of sampling of
shotcrete for the purpose of quality control shall be as agreed upon between the
Engineer-in-charge and the contractor.

PREPARATION OF THE SURFACES.
The preparation of the rock surfaces to be lined with shorcrete must be carried out
carefully. All loose and fractured rock shall be removed with adequate tolls and high
pressure water jets. Water seepage shall be collected in hoses and carried out of the
area to be lined with shotcrete. When minor infiltrations are wide spread throughout
the area and when it is difficult to collect them with hoses, it will be necessary to
provide weep holes through the shotcrete. When the shotcrete is required to be
placed in more than one layer old shotcrete layer surface shall be washed with a
strong air and water jet or by other means approved by the Engineer-in-charge before
applying successive layers the cost of such washing being included in the unit rate
for the items of shotcrete.
PLACING.
The first layer of shotcrete shall be applied immediately after the excavation which
will expose the rock surface and within a maximum time of 4 hour after blasting.
This operation shall be performed prior to or simultaneously with the beginning of
mucking operation. Along with the first shotcrete layer or simultaneously with the
same the contractor shall proceed to drill and install rock bolts. The rock surface area
266
up to distance of 1.00 m to 1.5 m from the heading face shall be covered with 1 st
layer of shotcrete.
The gun nozzle shall be placed normally to the surface and close enough to operate
efficiently without exceeding a distance of 1.5m for a 38mm diameter nozzle. The
discharge velocity shall be 125m/sec. and for a 25mm diameter nozzle the discharge
velocity shall be 150m/sec.
The velocity shall be uniform as recommended by the equipment manufacturer and
it will be measured by the instrument connected to the gun which shall be supplied
by the contractor, It is necessary that the water pressure be greater than the air
pressure to get complete dampening of the mix at the nozzle and to enable the
operator for an easier control of the gun. In order to prevent runoff a minimum period
of 30 minutes to 1 hour shall elapse between application of two consecutive layers
but the second layer will be placed before the first one has hardened. It is absolutely
necessary to put aside the rebound materials and the sand deposits from the surfaces
to be lined with shotcrete to receive a new shotcrete layer. When finishing, placing
of a layer its tree and shall be finished by gradually diminishing its thickness.
Construction joints with square ends shall not be permitted before starting the
placing of the adjacent layer, at a construction joint, the area having variable
thickness, it shall be carefully cleaned and dampened and the adjacent new layer will
be over lapped on it. The application of shotcrete will only be executed by qualified
and experienced operators for this type of work and the qualification of these
personnel shall be submitted to the Engineer-in-charge for his approval.
The thickness specified for the shotcreting shall be the minimum thickness anywhere
and no minus tolerances will be acceptable.
FINISHING.
All damage caused to shotcrete lining shall be repaired as directed by the Engineer-
in-charge by the contractor at his own expense. Where however lining have been
damaged due to blasting operations and in the opinion of the Engineer-in-charge
such damage could not have been avoided by suitable reductions in charge levels
and / or excavation patterns and sequence or / by differing the placing of the lining,
the repair of such damage as may be approved by the Engineer-in-charge shall be
paid for the finished surface of linings to be permanently exposed shall generally
follow the profile of excavation surface or a previously applied surface provided that
all abrupt changes in the profile are filled in so as to present at worst, a uniform
waviness. The normal surface finish shall be natural nozzle finish as left by the
nozzle when applied by an experienced operator and having a texture appearance
not less than as agreed between the Engineer-in-charge and the contractor on the
basis of trial specimens regarding abruptness or irregularities in the plane of the
surface and intensity of pitting protrusions.

Shotcrete lining shall be measured based on the theoretical area of the finished lining
measured along the payment line except in the area where over-break is due to
natural causes, in which case the payment for shotcrete shall be as measured along
the line of over-break, payment will be made at the contract rates per Sqm of
shotcrete lining of the thickness specified. The contract rate will include all labour,
material, equipment, fuel and tools necessary to execute the lining, inclusive of
clearing, curing etc. but placing of reinforcement wire mesh, which will be covered
267
under the item for supply and placing of wire mesh for reinforcement, shall be
measured and paid separately for the area in Sqm measured along the payment line
at the contract rate therefore in the contract. The rates shall cover all operations
required for furnishing the welded wire mesh, fixing in place with holding points,
overlap etc. The shotcrete price shall also cover the cost of the protection of all
drains, in the way shown in the drawings, including the supply, placing and latter
removal of the wooden plugs before starting the curing. The drilling of drainages
holes will be paid according to the corresponding items of drilling of the contract.

Payment shall be on basis of area covered by shotcreting in Square Meter. The rate
includes the cost of complete item including the expenditure on labour, materials,
equipments, admixtures, lighting & ventilation arrangement etc.
----------***----------
268
4.7 Providing and laying in situ vibrated M20 grade cement concrete
( Item No. TN 10(A),TN 10(B) & TN 11(A),TN11(B) )
Providing and laying in situ vibrated M20 grade cement concrete using 20 mm
clean, hard, graded aggregates for side and arch lining / Invert (Kerb and bed) lining
of tunnel through adit / itself & shaft including cost of all materials, machinery,
labour, formwork, batching, mixing, conveying upto placing point in agitator car,
placing in position, laying, vibrating, finishing, curing, ventilation, lighting, draining
and all other ancillary operations etc., complete with lead upto mode and all lifts for
Tunnel. (Excluding Royalty).
4.7.2 Scope of work
The Item shall include furnishing all materials equipment and labour for providing
and laying cement concrete lining at prescribed thickness. Providing and placing (a)
cement concrete (b) porous plugs (c) expansion / contraction and construction joints
wherever necessary or provided in design/ drawings. It also includes preparation of
sub-grade, for laying the concrete lining on bed / Kerb and sides / arch of tunnel,
curing of concrete lining for required period and all necessary quality control tests
on materials and lining by core test etc. all complete. It also include providing form
work (whenever necessary) furnishing all materials, equipment and labour
transportation, erection, keeping in place with necessary fixture and supports, oiling
and removing etc. all complete.
CLEARING SITE :–
The area proposed for lining as a whole shall be cleared and Any waste material
obtained from such site clearance shall be disposed off in a manner directed by the
Engineer-in-charge. The cost of this operation shall be deemed to have been covered
under the contract rates quoted for canal lining.
• Ingredients required for concrete i.e. cement, fine and coarse aggregates, mineral /
chemical admixture and water should satisfy the standard specification and relevant
IS codes.
• The concrete shall be generally governed by IS: 456-Latest version.
• Cement conforming to relevant IS codes shall be used.
ADMIXTURES :–
• Admixtures such as air entraining agents, plasticizers, superplasticizers, retarders,
Water Reducing agents, accelerators, shrinkage reducers, water proofing agents etc.
conforming to IS 9103:1999 (or latest edition) shall be added to concrete mix as per
the site conditions and requirement.
CORE TESTS :
• After curing of 28 days period, cores shall be taken at random to evaluate the quality
of concrete lining laid in respective reaches.
269
• Frequency of coring shall be, one core from bed lining and one core each from side
lining per 250 meter length of lining or additional cores if directed by the Engineer-
in-charge.
• In no case more than 3 cores shall be tested.
• The cores shall be prepared and tested as per IS:516-1959.
• The cores shall be examined and tested for its permeability (Kp Less than 10-9)
thickness(as per design/ drawing), density and compressive strength(As specified in
Mix Design).
• The contractor shall provide all facilities and cooperation towards extraction of
cores.
• The contractor shall make good to the holes of cores by refilling with same grade of
concrete.
• The testing of cores shall be carried out either in the Quality Control laboratory or
at any other laboratory that the Engineer in Charge may so decide (NABL
Accredited) and the results obtained shall be considered binding to the contractor.
• The contactor or his authorised engineer shall be given access to all operations and
tests that may be carried out as aforesaid so that he may satisfy himself regarding
the methods and procedure adopted.
• Payment shall be eligible only after the satisfactory core test results acceptable to
the Engineer as per IS: 456-2000.
• The rates quoted by the contractor shall be inclusive of all the testing. No separate
payment shall be made on this account.
• Concrete in the member represented by a core test shall be considered acceptable if
the average equivalent strength of the cores is equal to at least 85 % of the cube
strength of the grade of concrete specified and that no individual core has strength
less that 75%.
• Regarding particular tunnel reaches/ reach, though the lining be fully complete to
acceptable quality levels, such reach/ reaches will not qualify for acceptance for
payment till the associated works necessary for safety of lining during rains, such as
dowel banks, drainage etc. as per drawings are completed along with.
270
METHODS OF LAYING CEMENT CONCRETE LINING :–

• The concrete shall be generally governed by IS: 456-Latest version. Concrete lining
of specified grade shall be laid in the side and arch lining of tunnel as shown in the
drawing.
• The mix of the concrete shall be designed in the laboratory before starting the work.
The mix as designed shall be adopted till there is no change in the source of the
materials.
• Cement conforming to relevant IS codes shall be used.
• Mechanized placement of lining shall be done through deployment of concrete
Paver, Baby Paver, (Slope Gantry Paver) and slip form steel gantry etc.
• A full section concrete Paver covering the tunnel (both bed and side) can also be
used depending upon the c/s of channel & bed profile for mechanized placement of
lining in the entire c/s in a single operation. The Paver after it had placed concrete
in convenient panel length shall be moved forward to place concrete in the next
panel & so on.
Where the bed width is less and lining is required to be placed manually, mobile
slip form steel gantry (fitted with vibrator on steel plate ) shall be used for placement
of concrete lining.
When the lining is carried out manually, the concreting shall be done panel wise
along the slope and in alternate bays, the size of the panels shall be as per the
drawings or as directed.
• Concrete shall be laid in one depth of specified thickness. The top finished surface
of the concrete shall be in line with section of the side and arch. After concrete is
laid to full depth, it shall be compacted thoroughly by tampers and /or wooden
sleepers or the concrete shall be compacted by mechanical plate or screed vibrators.
• If the area on which the concrete is to be placed is under water, it shall be pumped
dry and kept so throughout the period of laying concrete and 12 hours thereafter,
without any damage to the concrete.
• The rate of the lining items shall include the cost of any dewatering so required.
• The protective lining proposed to be placed u/s & d/s of structure in small reaches
may be placed in conventional / manual manner. Also in any such small reaches or
other locations where mechanised lining is not considered feasible Engineer-in-
charge may allow manual placement of lining on both bed & sides.
• Concrete shall be placed only in the presence of a well experienced engineer duly
appointed by contractor.
• When concrete placing operations are stayed for the day or are interrupted because
of break down or are delayed by other causes or where the contractor elects to
construct a joint, the edge of the fresh concrete lining shall be bulk headed to a
surface normal to the lining along transverse and longitudinal lines. Before placing
operations are resumed, the surface of hardened concrete shall be prepared as a
construction joint.
Whenever a substantial break-down occurs in the concrete production or concrete
transportation system, a joint should be formed as close to the face of the fresh
concrete as possible.
• All concrete on the new side of the joint shall be removed. The fresh concrete shall
then be placed against the existing concrete with the full groove for required
contraction joint formed in between them. This is essential to eliminate cold joints.
271
• End Profile wall shall be provided at such locations as at the commencement of
protective lining upstream of structure and also at end of this lining downstream of
the structure and at all such locations where the lining commences and ends, prior
to release of water in order to avoid any damage to the lining.
SLUMP :–
A slump as per mix designed shall be considered adequate at the placement site from
considerations of proper discharge of concrete from the transit mixer / agitator cars,
mechanical mixer, and ease of placement and attaining a well consolidated lining
with a good finish.
A proper record of slump measurement for every 2 hour per mixer shall be
maintained.
CONCRETE PRODUCTION AND TRANSPORTATION :–

• Concrete shall be produced in a stationary weigh batching plant/ plants of adequate
capacity installed at suitable place/places by the contractor and concrete conveyed
to the placement site/sites in mobile transit mixers for placement of concrete lining
with fully mechanized concrete paver/ pavers.
• No manual concrete making shall be allowed.
SURFACE FINISHING :–
• Concrete shall be finished to even and smooth surface free from pockets or exposed
aggregates. This shall be obtained by careful use of long handle steel trowel. Any
remaining roughness shall be rendered smooth with cement mortar 1:3 proportion
without lapse of time, after laying of concrete and removal of shuttering if used.
•
UNDER DRAINAGE :–
• A lined canal where the ground water level is higher or likely to be higher than water
level inside the canal so as to cause damaging differential pressure on the linings; or
where the sub grade is sufficiently impermeable to prevent free drainage of the
underside of linings in case of rapid draw down, under drainage should be provided
in accordance with IS 4558 : 1983 (or latest edition).
• Wherever specified and shown in drawing, porous concrete plugs of 100 mm dia
and 300 mm length shall be provided in bed and side slopes underlain by graded
filter of size 400 mm by 375 mm or any other size as per drawings or directed by
• Porous block shall be casted using one part of cement and 4 parts of 20mm coarse
aggregate by weight. No sand is to be used. Only so much water shall be used in
concrete as is required to produce a paste which will coat the particles without filling
the voids. While casting porous concrete in moulds, care shall be taken to ensure
that it is not over tamped or compacted so as to reduce its porosity.
• The porous concrete after curing shall be pervious and free draining type. As soon
as the concrete hardens it should be kept fully moist with water for at least 14 days.
TEMPERATURE OF CONCRETE :–
• Temperature of concrete as placed, critical to cracking control and durability, shall,
preferably not exceed about 320C (900F)
• Placement of concrete in hot weather shall be done during the morning and evening
hours, extending to night hours as required.
272
• For work in extreme weather conditions, the procedure set out in IS 7861(Part-1) or
IS 7861(Part-2) be scrupulously followed.
CURING OF CONCRETE LINING :–

• Appropriate methods for continuous curing of the lining for the prescribed period
shall be carried out.-
• Twelve hours after laying of concrete, small bunds longitudinal and cross-wise
consisting of earth materials or lean cement mortar should be laid for a height of 8
cm for the purpose of bed curing. Water will be kept always ponded in the bunds for
28 days continuously.
• The panels in which concreting is done on previous day shall be covered with burlap
or jute cloth or gunny bags stitched at its end, to for full slope width of lining
immediately. All exposed area of concrete will be covered with gunny bags etc and
the surface so covered shall be kept continuously in wet condition by mechanical
means throughout the curing period.
Curing by MEMBRANE FORMING CURING COMPOUND :–

• The white pigmented curing compound confirming to ASTM designation of C-309-
81 (or the Indian manufacture confirming to International Standard of C-309-81)
shall be used to form water retaining membrane on the surface of concrete.
• The curing compound shall be used only after satisfactory test results are obtained.
• The curing compound shall be applied immediately after the bleeding water shine
disappears leaving a dull appearance on concrete surface.
• The liquid compound shall be kept continuously stirred mechanically in a drum and
sprayed uniformly over the concrete surface.
• A thin continuous film shall be formed over the lining surface so as no moisture in
green concrete is lost due to evaporation.
• One liter of curing compound shall cover about 4.00 Sq. m. of concrete surface.
Accurate coverage should be based on laboratory and field trials.
• Laboratory test shall be carried out to check that with specified coverage, the loss of
water does not exceed 0.55 kg/Sqm over a period of 72 hours.
• Other tests relate to reflectance and drying time. Day light reflectance of white
pigmented curing compound shall not be less than 60% of that of magnesium oxide.
• The drying time requirement specifies that the curing compound could be dry to
touch in not more than 4 hours.
• When the curing of concrete lining is not found satisfactory, the Engineer-in-charge
may direct the contractor in writing to resort to second layer of membrane curing or
mechanized water curing.
JOINTS:
Joint with sealant:-
• Contraction joints shall be provided and treated as shown in the drawings or as
• Expansion joints shall be invariably provided where structure intersects the canal
lining.
• Transverse contraction joints shall be spaced at a maximum spacing of 3.0 m center
to center.
• Longitudinal joint shall be provided at about 18 times thickness of lining below the
top edge (viz. about 1.35 m for 7.5 cm thick lining)
273
• The shape, spacing, and dimensions of contraction joints shall be as shown in the
drawing.
• The joints shall extend to at least 1/3 of lining thickness (viz.2.5 cm for 7.5 cm thick
lining) with a top width 14mm maximum and tapering to 11mm to join a 450 groove
at bottom. The contractor must ensure that the grooves are of specified dimensions,
acceptable to the Engineer-in-charge.
FILLING OF JOINTS :–
• Filing of joints shall be taken up only after a minimum of 28 days setting period of
CC lining.
• The grooves shall be cleaned thoroughly to their full depth and width by brush, air
jet, water jet etc. All loose particles and foreign material shall be removed and the
grooves shall be thoroughly clean and dry so as to ensure good adhesion to the
sealant.
• The primer shall then be applied by means of brush or any other suitable applicator
to cover the sides completely before the application of prepared sealing compound.
COMPOSITION OF SEALANT :–
Unless otherwise specified, the sealant shall be prepared from the following materials:
• 1. Bitumen 85 / 25 = 55%
• 2. Sand (Fineness modules 1.00 to 1.50) = 43%
• 3. Asbestos powder (of white color) =2%
PROCEDURE :–
• The sealant shall be prepared by heating the bitumen to 3750 F and
sand also to the same temperature separately.
• The sand shall be mixed with 2/3rd quantity of bitumen first and then asbestos
powder shall be added to it. The remaining 1/3rd quantity of bitumen shall then be added
to this mix and stirred thoroughly.
• The grooves shall be covered with wooden strip a long and held on slopes with the
help of clay puddle put along the sides. The wooden strips shall be coated with grease
on inner side so that it may not stick to the filler compound. The wooden strip shall be
gently removed after about 30 minutes and the next joint shall than be filled in similar
manner. The joint shall be finished with a hot trowel and any hole shall be refilled with
sealant.
• Filling of joints shall commence from bottom of slopes.
• 5.11.2 PVC Strips: -
• Concrete pavers are fitted with fixtures for insertion of PVC strips for contraction/
expansion joints while placing of concrete for lining.
• The contractor shall get the PVC strips material as per specification or approved
from the Engineer-in-charge prior to its use in the C.C. Lining.
• Note: As and where Engineer-in-charge determines that PVC strips in the
contraction joints are not feasible of proper insertion, he can direct the contractor to
adopt the process of cutting grooves in the concrete lining.

• Measurements should be on cubic meter basis.
• All linear measurements shall be in meter correct to 0.01 m.
• The perimeter of lining shall be of the top finished surface of the lining.
274
• Payment for lining shall be made for the thickness shown on the drawing and on per
cubic meter basis of the surface area including horizontal keys on both sides at the
lining top.
• The thickness of lining shall be cross checked by (i) Volume of concrete placed and
area covered; (ii) use of probe when concrete is green and plastic; (iii) random coring.
• Contractor shall submit the measurements record drawings (L-section & Cross-
Section) and quality assurance reports of the executed work which includes all test
results at required frequencies for materials, workmanship, core test, result analysis.
TOLERANCE IN LINING THICKNESS :
The permissible tolerances for the lining thickness shall be 10%, provided average
thickness is not less than designed thickness.

• The rate of the lining items shall include the cost of any dewatering so required.
• The cost of the admixture, mixing with concrete and placing it, shall be included in
the unit rate of concrete in the contract..
• Payments shall be done based on measurement recorded after satisfactory quality
assurance report. The Engineer-in-Charge will be responsible to verify and accept the
report before accepting the measurements.
concrete for specified period etc all complete.
ACCEPTANCE CRITERIA OF LINING :–

• In case the concrete does not conform to the acceptance criteria for specified strength
(Acceptance strength criteria for core shall be as per section 17.4.3 of IS: 456-2000),
density, permeability & thickness etc., the Engineer-in -Charge reserves the right to
reject the work or accept the same at a reduced rate derived from contract rate if
approved by the competent authority after examining all aspects and provided the
structural integrity is not affected.
Sr.
Item Percentage of Payment
No.

2
Or measurement of portion for Final. 100%
MODE OF MEASUREMENT AND PAYMENTS FOR POROUS BLOCK:

The porous blocks provided for under drainage will be paid per No. basis.
275
MODE OF MEASUREMENT AND PAYMENTS FOR JOINTS:
Payment of contraction and expansion joints shall be on running meter basis.
Note:-Specifications for MISCELLANEOUS ITEM are applicable for all above item
under tunnel section.
----------***----------
276
4.8 MISCELLANEOUS ITEM
4.8.1 LIGHTING:
All lighting arrangements listed in the following paragraph shall be considered as items
of underground excavation and no extra payment shall be made.
1) For each tunnel, shaft, caverns, etc. the contractor shall provide a lighting system
which shall be maintained in operation during the execution of all underground works.
Besides the general lighting system, he shall provide special lighting for the excavation
face, where any work is being executed or where it is necessary to inspect a part of the
excavation. This lighting system shall be integrated by flood lights, air-driven lights or
any other type approved by the Engineer-in-charge. Energized wires or lamps and naked
bulbs shall not be permitted in the immediate vicinity of the work face at the time of
charging and blasting. Lighting of flame shall not be permitted in any part of the
underground excavation unless the Engineer-in-charge authorises it for specific working
conditions. All the underground excavations used as many ways or through which
persons pass should be kept effectively white washed within 100 m from the farthest
face. Particular care should be taken at places including junctions, siding, bypasses
engine room, place containing motor, or other apparatus, first aid station etc.
2) All power and lighting wires shall be installed and maintained in optimal conditions
of insulation and safety confirming to the Indian Electricity Rules, 1956 of Government
of India. Power and lighting wires shall be installed on one side of the excavations and
the detonator wires shall be installed on the opposite side of the excavation and at
sufficient distance from leads of telephone communication systems.
3) All electrical cables and wires shall be firmly fixed on excavation wails by means of
insulators of adequate design and capacity and their installation shall be made in such a
way that wires do not get damaged during excavation. The Contractor shall provide
sufficient lighting to ensure the following in all places where work is in progress.
i) Safe working conditions are provided for the contractor’s personnel, and the
Engineer-in-charge occasional visitors etc.
ii) The work can be constructed in complete compliance with the contract.
iii) The complete inspection of all works in progress can be made by the Engineer's
representative.
4) Unless otherwise directed by Engineer-in-charge, the minimum service luminance on

ground or working surface to be provided for the various operations or work areas shall
be as tabulated below.
277
Sr. Operation of area Luminance minimum measured value
No. in lux
1 Concrete placing 50
2 Underground works (working faces) 100
3 Junction 50
4 Operator's cabin of machines 50
5 Maintenance shops & auxiliary buildings 200
5) If any agency other than the contractor is working in underground excavations, and this
other agency avails of the lighting facility, the contractor shall provide this facility at no
extra cost.
4.8.2 VENTILATION:
1. The contractor shall furnish and install in each one of the underground works, working
face and each tunnel, a ventilation system which will be maintained in operation during the
time in which the work is being executed to the satisfaction of the Engineer-in-charge. The
ventilation system shall consist of reversible axial flow fans inside the ventilation ducts. The
ventilation equipment and ducts shall be of good quality so that a continuous and efficient
service is guaranteed. It shall have an adequate capacity, can be firmly fixed and shall be
sufficiently to withstand the work pressures. The tail end of the ventilation duct shall be
taken as close to the heading as shall be safe from blasting. The contractor shall before
initiating any underground work submit for the approval of the Engineer-in-charge complete
layout, plan and methodology of ventilation system, duly backed up with derailed
calculations justifying the deployment of ventilation equipment and accessories proposed
by him, including the capacity of blowers, diameter of duct, defuming time etc. before
initiating any underground work. The contractor shall not work without this approval which
however does not relieve him from his obligation to provide sufficient fresh air for
underground work, If during the execution of the work, the Engineer-in-charge finds that
the capacity of the ventilation system is inadequate for the good health of the worker and
speedy removal of gases, he shall order the contractor to install additional fans and take all
necessary measures to obtain the desired results.
2. The ventilation system shall normally be in "blow in" mode (viz. forcing fresh air to the
heading ) except during blasting and defuming when it will be reversed to the "suck out"
mode to speedily remove blast dust cushion and noxious gases through the duct and fresh
air moving into the excavation/tunnel. The ventilation system shall have the capacity to
ensure that after every blast round dilution of CO2 and oxides of Nitrogen in the blasting
fumes of 50 PPM and 5 PPM respectively, is achieved within a period of 5 minutes. Com-
plete defuming from the heading or working place should take place within 20 minutes. It
shall also ensure that at every place inside underground where persons are required to work
or pass, the air does not contain less than 19.5% oxygen or more than 0.5% of Carbon
278
Dioxide or any noxious gas present in quantity to adversely affect the health of workers.
The contractor shall have no right to any compensation or to term extensions for this reason.
3. The Carbon Monoxide (CO) content and the percentage of oxygen in the air shall be
measured and checked regularly half an hour after each blast with interval at suitable
intervals to see that they are within prescribed limits. The contractor shall make full ar-
rangement for such periodical check (which shall not be less than twice in a week) whenever
Engineer-in-charge desires. If the CO content in the air exceeds 50 PPM or the percentage
of Oxygen in the & air is less than 19.5% at any place, immediate remedial measures shall
be taken and until the ventilation improves to acceptable limits given above work may be
continued to be done if authorised by Engineer-in-charge but at a rate reduced by 10% of
the contract price such instances however would be rare if the case situation arisen
frequently action as indicated in Para 2.33.4 below will be taken by the Engineer his sole
discretion.
4. The work however shall be stopped after the CO content exceeds 60 PPM or the
percentage of Oxygen reduces below 19 % In case of persistent failure to adhere to the
standards and requirements laid down above either of following two actions may be taken.
a) The Engineer-in-charge shall install and operate at the cost and risk of the Contractor,
such supplementary ventilation facilities as he may deem necessary.
b) The Engineer may terminate the contract after giving due notice. Persistent failure will
also invite action against the contractor under the relevant laws of the country.
5. The ventilation system in each work face shall meticulously meet the following air
requirements..
I. Requirement of fresh air for diesel operated machinery 4.5 to 5.0 m cube of air per minute
per H.P. of diesel equipment for diluting the toxic fumes in the exhaust gases.
II. Requirement of air for personnel 4.25 cum per minute per person in the underground
work. In addition to the above, the ventilation system shall also meet the following
requirements.
(i) The capacity of blowers and their spacing is such that all gases and dust resulting from a
blast are expelled within a period of time not exceeding 20 minutes, to enable resumption
of tunneling operations immediately thereafter. No person shall be allowed to enter the place
where blasting has been carried out unless a period of at least 15 minutes has elapsed from
the time of blasting.
(ii) Ventilation and exhaust system for the excavation of caverns, tunnels and shafts shall
be of sufficient capacity to maintain an adequate supply of uncontaminated pure air at all
points.
The design of ventilation system shall take into account, factors such as length of heading,
size of tunnel / shaft / caverns, amount and type of explosives used, frequency of blasting.
temperature humidity and safe limits of endurance for human being to toxic gases.
279
(iii) Leakage through joints of duct lengths shall be minimised by inserting rubber gaskets
an allowance of at least 20 % shall be made for leakage while estimating total air
requirement
(iv) The speed of return air in tunnels shall not be allowed to drop below 20-25 meter per
minute.
6. The sealed ventilation dust provides fresh air to the heading. In order to improve
conditions in the rest of the tunnel and particularly at intermediate work points, the con-
tractor shall where necessary provide additional blower at the growing level along with few
extension pieces of ventilation duct at both ends. This supplementary arrangement shall
cause local stirring of air and help in speeding the return air flow.
7. The contractor shall keep spare sets of blowers and motors so that in the event of failure
of a blower or a motor or both, prompt replacement is made by him. Likewise, he shall stock
sufficient number of spare starters, switches etc.
8. All the ventilating arrangements specified in this section shall be considered as part of
the items of underground excavation and no extra payment for this shall be made.
4.8.3 NOISE CONTROL:

1. Noise level shall not exceed the limits specified in this section. Should the noise levels
exceed these specifications, suitable engineering or administrative controls shall be utilised.
If such controls fail to reduce sound levels within, the specified limits, the contractor shall
provide personal protective equipment to reduce sound level to the specified limits. The
following standard shall have to be maintained in underground excavations.
2. i) A working limit value of 85 dB(A) continuous may be set as the level below which
very little risk to an unprotected ear, or hearing impairment exists for an eight hour exposure.
ii) The danger limit value shall be 90 dB(A) above which the danger of hearing impairment
and deafness may result from an unprotected ear.
iii) A worker should not be allowed without appropriate ear protection to enter an area in
which the noise level is 115 d(A) or more,
iv) Personal protective equipment shall be worn, if there are single isolated outbursts of
noise which can go above130 dB (A) impulse Or 120 dB(A) ‘fast’
v) No worker shall be allowed to enter an area where the noise level exceeds 140 dB(A).
3. In all cases where the sound levels exceed specified limits, a continuing, effective hearing
conservation programme shall be administered. Sound pressure level measurements shall
be made by the contractor using qualified personnel using calibrated instruments. Noise
hazardous areas (greater than 85 dB(A) continuous or 130 dB(A) Impulse or 120 dB(A)
'Fast') shall be marked with caution signs indicating both the hazardous noise levels and the
need for hearing protection.
280
4. All arrangements made for noise protection and control shall be considered a part of items
of under growing excavation and no extra payment shall be made.
4.8.4 DUST CONTROL:

1. The average allowable concentration of dust in the work front during each shift/to which
each worker is exposed at any working point or place, shall not exceed 3 mg/m2 This limit
value will be applicable when the repairable dust where dust contains 5% or less of free
silica in air born dust. Where dust contains more than 5% quartz or free silica, the limiting
value shall be determined by the following formula. Percentage of repairable quartz or free
silica mg./m3
2. All repairable dust concentrations shall be measured by the NCB/MRE Dust type 113 A
of UK or its approved equivalent.
3. The minimum frequency for determination of the repairable dust concentrations shall be
once a month at different working points.
4. If the concentration of dust particles below 5 micron size exceeds the prescribed limits,
dust control measures including wetting of dust producing surfaces such as areas to be
blasted, loading and unloading points, dusting or dressing points etc. shall be undertaken.
Suitable dust respirators must be wore at places where the dust level exceeds the prescribed
limit.
5. From the drilling and blasting of view the dust control measures include:
i) Wet drilling: In addition, to wet drilling, there shall be (a) adequate ventilation for dust
control and (b) periodical medical check-up of workers in tunnel to confirm fitness,
ii) Before any shots are fired, the roof/back, hanging wall, foot wall and sides in the vicinity
shall wherever practicable and unless naturally whenever wet throughout, be thoroughly
wetted with water,
iii) As far as practicable, the time for shot firing shall be so chosen that a minimum number
or persons are exposed to dust.
iv) After shots have been fired (a) airborne dust in the place shall be actively removed by a
current of air and (b) after the place has been examined and declared safe, the face walls and
sides and all loose rock within a radius of 4.5 m of the site of blasting shall be thoroughly
wetted with water,
v) Dust suckers may be used in dust laden atmosphere.
vi) METAL DUCT SHALL CONFIRM TO IS 655-1963:
Duct line may be laid either on the floor or hung from the side wall excavation depending
on convenience and other economic aspects of ventilation. However, care shall be exercised
to see that all the joints of Duct line are airtight to avoid losses due to leakages.
vii) BLOWERS:
The reversible type of axial blowers fitted directly on totally enclosed electric motor is
recommended for ventilation of tunnels. It, is a normal practice to fit two such units in one
to increase the total output.
281
The diameter of pipes shall be fixed after taking into account the frictional resistance of air
flow through the pipes and other relevant factors. Some length of the air duct near the
working face should be kept flexible. For longer length of tunnel additional boosters at a
suitable place may be necessary.
6. All arrangements made for dust control shall be considered parts of items of underground
excavation and no extra payment shall be made.
4.8.5 COMMUNICATION FACILITIES.

1. The contractor shall install maintain proper communication facilities in good working
condition at all times during the whole period of construction for prompt telephone
communication between all important points within underground works and between
underground works and the surface. The contractor shall also install, maintain and operate
such other communication and signal facilities as may be necessary for the safe and efficient
execution of the work. All such facilities shall be subject to the approval of the Engineer-
in-charge. Authorized employees of Corporation shall have free use of such communication
and signal facilities.
2. The entire cost of providing and maintaining such a communication and signal system
shall be deemed to have been included in the unit rates contracted for excavation.
4.8.6 DRAINAGE AND PUMPING:

1. All relevant provisions of specification for excavation and dewatering section 2 & shall
be applicable for drainage and pumping herein.
2. For effective dewatering, if a channel or a gutter has to be excavated outside the

prescribed line of excavation, the contractor may excavate such channel or gutter with the
approval of the Engineer-in-charge. Such channels or gutters shall be filled back by the
contractor with concrete of such quality as specified for the lining of tunnels The excavation
and back filling of such channels-or gutters shall be carried out by the contractor at his cost.
3. No Payment for dewatering shall be made as for the work specified in Para.2 above, as it
is included in the rate for the excavation.
4.8.7 MONITORING OF UNDERGROUND EXCAVATIONS BY

INSTRUMENTATION:
1.Comprehensive measurements of instruments such as single and multiple point bore hole
extensometers, tape extensometers, rock bolts, load cells, pore pressure cells, etc. shall be
undertaken regularly to monitor the behavior of the caverns. The measurements shall
include roof and wall behavior, convergence in roof and walls, behavior of shear/fault zones,
magnitude of pore pressure, loss of pretension of rock bolts, etc. Rate of movement in excess
of 0.05 mm/day or even a slower but continuous rate being indicative of a dangerous
situation, shall be promptly taken care of.
282
2. A series of multiple point borehole extensometers of 30m depth shall be installed in the
roof during the heading excavation so as to monitor the behavior of cavern roof during its
excavation. This will also establish the adequacy of the roof roof support.
Similar instruments shall be installed progressively on the cavern walls as the excavation is
lowered. Particular care shall be exercised to monitor the mid-height points of the cavern
walls.
3. In addition to above, instruments shall also be installed in other underground works or on

surface where special geological features are encountered.
4.Observations of instruments shall flash a timely indication of the overall behavior of the
cavern. Any additional stabilization measures considered necessary in the light of these
measurements shall be immediately undertaken and completed by the contractor.
5. Readings shall be continued even after excavation of the caverns is completed. The
contractor shall provide all necessary facilities for the installation of such instruments
including" provision of borehole of 30 m depth in different array, and observations. The
contractor shall also provide facilities for construction of a central observation cabin to
locate the date logging system and to lay electric cables for connecting the data logging
system with the instruments.
6. Engineer will supply a general instructive plan for all such instrumentation to be provided
in cavern, and contractor shall provide all help without any cost as mentioned above from
time to time for installing all such instruments as instructed by the Engineer-in-charge.
4.8.8 CLEANING OF TUNNEL:
On completion of the excavation etc. Tunnel shall be cleaned off all muck and other
installation and equipment except that necessary for later concreting and grouting to the
satisfaction of Engineer-in-charge. The cost is included in the item of excavation itself.
4.8.9 Dewatering and Drainage Measures
Depending on the amount of encountered water inflow from karst features adequate and
timely dewatering and drainage measures shall be performed. Where an on going
constant water inflow through the karst feature is identified adequate measures for
dewatering and drainage shall be installed, e.g. collecting the water inflow with plastic
hoses connected to the drainage system.
4.8.10 Safety Precautions

(1) For drill and blast excavation, only Non-Electric detonators (NONEL type) shall be
used. However, at the discretion of the Engineer in Charge and under special
283
circumstances, it is decided that electric detonators may be used instead, the following
precautions shall be strictly adopted: A separate circuit, independent of power and light
circuits, shall be used for blasting. No electrically energized circuit shall be installed on
the same side of the tunnel with the blasting circuits. All electric lights or other energised
circuits shall be disconnected for at least 70 m from the point of loading. For loading
purposes, the employees shall be equipped with permissible battery lamps. Adequate
warning notices shall be given to all persons employed indicating the period, or danger
at the time of firing and it shall be the duty of the CONTRACTOR to provide adequate
shelters or screens for protection of workers exposed to risk of injury from the explosion
or from flying material. After the blast takes place in the tunnel, the workmen shall not
be allowed to go to the face till all the toxic gases are evacuated from the face.
(2) Careful and proper scaling after each blast is imperative. The support elements are
considered to be sufficient for the overall stability of the tunnels. However, the
CONTRACTOR shall perform the installation of local rock bolts as required to prevent
loosening of rock blocks in the immediate heading area. Periodical inspection of the
tunnel sidewalls and roof areas shall be performed by the CONTRACTOR to detect
possible cracks or signs of instability of the tunnel support. Assessment of cracks shall
be made in association with the results of the geotechnical measurements in cooperation
with the EnC.
(3) In rocks with rock burst potential, scaling-, shotcreting and rock bolting equipment must
be used which allows to be operated from a safe distance from newly exposed rock
surfaces.
(4) Blasting will be permitted only after proper precautions have been taken for protection
of all persons, work and property.
(5) Drilling, blasting, excavating and shotcreting operations shall be conducted by methods
and with equipment which shall positively control dust, fumes, vapours, gases, fibers,
fogs, mists or other atmospheric conditions. Following each round, the broken rock or
muck pile shall be wetted down sufficiently to prevent excessive dust during mucking
operations.
4.8.11 PRECAUTIONS FOR HANDLING AND TRANSPORTATION OF

EXPLOSIVES
All pertinent specifications regarding the general requirements for storage and care of
explosives as detailed in item 2 of the contract specifications shall be applicable.
i) Only permissible explosives, and in the manner as specified by the appropriate authority
shall be used.
284
ii) General safety regulations in all blasting operations shall confirm to prescribed regulation
on the subject codified by Indian Explosives Act and relevant BIS code of practices.
iii) Smooth/controlled contour blasting techniques shall be deployed in tunneling, shaft

excavation and the enlargement of caverns through benching. Blasting plans for these
underground components shall be evolved after detailed test/trial blasting involving various
parameters e.g. design of cut, location of cut depth of round, design of contour holes, wall
and floor holes, diameter, burden and spacing of production holes, charge concentration etc,
with the approval of the Engineer-in-charge and thereafter adhered to any changes needed
during the course of work shall be duly reported to and got approved from Engineer-in-
charge.
iv) Blasts shall be designed to keep ground vibrations within permissible limits, as
prescribed by Engineer. Suitable vibration measuring arrangement shall be made by the
Contractor and record of such monitoring shall be kept in registers.
v) All poisonous and noxious fumes and dust cushion, resulting from the heading blast, shall
be sucked out and diluted to a safe level at the face through effective ventilation system
comprising of exhaust and inlet system of adequate capacity. The air ducts provided shall
be of such a size as not to allow too much pressure drops. Rubber gaskets shall be used, at
all joints, while extending the ducts to reduce air leakage. Good working conditions shall be
achieved at each tunnel face and throughout the tunnel length through proper spacing of
blowers.
vi) Good visibility shall be maintained at all times throughout the underground
network and an excellent visibility, at all working faces though proper lighting including
flood lighting.
4.8.11 UNDERGROUND TRANSPORTATION AND STORAGE:

Relevant provisions contained in item 2, here before, shall generally apply. The following
additional precautions shall be observed.
i) Explosives and detonators shall by placed in separate insulated containers/ carriers

whether carried by persons or conveyed by mechanical means. The doors of the carrier for
the explosives and detonators shall open on opposite sides of the carriage and kept locked,
except when loading and unloading. The cars of carriers shall have 45 cms open space
between explosives and detonators and nothing whatever shall be carried in that space. An
attendant shall ride with the explosives when conveyed by mechanical means on slope, in
shafts or in underground work areas. For carrying of explosives by mechanical means prior
permission of Chief Inspector of Explosives shall be obtained.
ii) Insulated containers used for carrying explosives or detonators shall be constructed of
finished wood not less than 50 mm thick or plastic not less than 6 mm thick, pressed fiber
not less than 10 mm thick. The containers shall have no metal parts, no nails, screws, bolts,
etc/and it shall be water proof and provided with a lid. The container shall be provided with
suitable non-conductive handling device such as a rubber, leather or canvas handle or a
285
strap, prior permission of the Chief Inspector of Explosives shall be obtained for use of
plastics in the containers for carrying explosive.
iii) Cars used for transportation of explosives shall not be loaded beyond their rated capacity
and explosives shall be secured to prevent shifting of load or dislodgment from car in transit.
All cars transporting explosives shall be marked or placed on both sides and ends with the
word' EXPLOSIVES' and provided with two red flags during the day time and during night
time by two red lights. Car transporting explosives shall be equipped with at least two fire
extinguishers.
iv) Cars shall be pulled and not pushed when being moved by the locomotive and there shall
be one empty car between the locomotive and the car containing explosives.
v) Explosives and detonators shall be brought to the working places in separate tight, well
insulated containers, and kept in the containers until removed for placement in drill holes.
If drill holes are not ready, they shall be stored in locked box type magazine located at a
safe distance, at least 170 m from the working face.
4.8.12 MISFIRES:
Special precautions regarding misfires as listed in item 2 of Contract specifications shall be
taken by the contractor.
i) When misfires occur action shall be divided into two parts, the first dealing with
immediate solution and the second consisting of an analysis of why the misfire occurred and
what can be done to avoid repetition, including seeking qualified professional assistance, if
need be.
ii) No attempt shall be made to fire a hole or holes which have misfired before a very careful
examination of the site conditions has been made. It is possible that burdens on the misfired
hole/s will have been reduced to an unsafe level, and that blasting could result in rock
projection over many times the normal distances.
iii) a) Where the hole cannot safely be fired, the charge shall be retrieved. In horizontal
holes, this shall be done by washing the charge out with a jet of water or compressed air. In
vertical holes it may, as a last resort be necessary to fire short holes in their vicinity. Great
care must be taken so that the holes drilled for this purpose are angled away from the charge.
b) When using electric detonators, where the detonator leads are accessible, the individual
assemblies shall be checked for continuity. If the test gives a positive result, the hole/s shall
be fired. It shall be advisable to use another tested exploder and the cable shall be examined
carefully for faults before the attempt to fire is made.
c) Where the leads are inaccessible or where the test for continuity gives negative results,
the hole/s shall be re-primed. The stemming shall be washed out with water and new primes
inserted.
286
4.8.13 Drainage during Construction
1. Scope
(1) The CONTRACTOR shall install, operate and maintain all temporary pumping plants
and drainage facilities and remove all accumulated silt, suspended solids and debris
necessary for the proper execution and completion of the works at his own cost. Standing
water will not be allowed. The CONTRACTOR shall drill probe holes ahead of the
advancing tunnel face and grout suspect areas or pre-install drainage to divert the
underground water before excavation to control or decrease the inflow volumes so as to
excavate successfully and avoid instability.
The CONTRACTOR’s proposed methods and strategies for groundwater control shall be
presented in the CONTRACTOR’s Method Statements.
(2) The capacity of pumping plant installed and maintained shall be at least two times the
expected volume of water inflow. In addition, pumps shall be provided at each working
heading of sufficient capacity to maintain acceptable working conditions for excavation and
construction of the lining.
(3) No less than three pumping units shall be installed and maintained at each heading to
permit maintenance and repair without shutting down pumping operations.
(4) Provide and maintain at each face standby pumps and pipe work of capacity at least
equal to the normal inflow of water. The standby pumps and pipe work shall be ready for
immediate installation as extra capacity to cope with any sudden large inflows that may
occur.
(5) Comply with all applicable environmental requirements to minimize effects on the
groundwater table.
(6) The CONTRACTOR shall remove the temporary drainage system, including pipes, after
completion of the Works at his own cost, except where permanently embedded.
(7) Where exposure to water causes deterioration of ground, drainage water shall be piped,
not channeled.
(8) During excavation of the tunnel, the CONTRACTOR shall maintain a ditch on one side
of the tunnel, clear and free of silt and debris at all times and keep the aisles dry. Temporary
collection sumps shall be cleaned and pumps shall be maintained in good condition at all
times.
Fences and warning signs shall be placed around sumps. The tunnel roadways shall be kept
trafficable at all times by appropriate water control and by placing of firm road surfacing
material, or by other means as required.
(9) The CONTRACTOR shall carry out free unhampered gravity flow and/or continuous
pumping in the presence of water in the tunnel. Water shall be controlled at the heading,
287
keeping the tunnel invert and any tunneling machinery clear of water as much as practical
at all times.
(10) The CONTRACTOR shall take all actions necessary to prevent pollution of creeks,
rivers and other water bodies by clay, silt, oil, grease or other pollutant. The
CONTRACTOR shall comply with all standards set up by local authority.
(11) Water pumped or drained out of tunnels shall pass through oil skimmer or other oil
separator, then through sedimentation basin designed for the maximum expected flow.
Construction fencing of 1.8 m minimum height or other effective protection shall be
installed to prohibit unauthorized persons from trespassing into the area of the sedimentation
pond.
(12) The inlet to the ponds shall be designed so that water discharged into the pond will not
stir up sediment previously deposited in that basin. Provision shall be made to repair or clean
the basin during the progress of the works. The outflow channel from the pond shall be
designed and constructed such that soil erosion is prevented. To ensure the continuing
satisfactory operation of the system, accumulations of sand, silt, oil and sludge shall be
periodically removed and disposed off to places approved by the relevant authorities.
(13) Drainage during tunnel excavation shall also comply with all requirements of Lift
Irrigation scheme.
2 Materials and Execution
(1) Longitudinal Drainage: The tunnel shall be drained by trenches in the bottom of the
respective heading. In areas of large water inflows, installation of partly perforated or slotted
hard-PVC pipes with a diameter of 150 mm to 300 mm depending on the amount of water
to be diverted may be necessary.
(2) In case of descending headings sumps shall be provided at regular intervals from where
the water shall be pumped out of the tunnel.
(3) Radial Drains: For concentrated water inflows, relief holes shall be made into the ground.
Perforated hard-PVC pipes, diameter 40 mm, shall be installed into the holes. The space
between the pipe and mouth of the borehole shall be sealed with quick setting mortar. Quick
setting mortar is a material which provides setting and hardening within a couple of minutes
used for temporary fixation or sealing. No specific properties are required. The mouth of
the pipe shall be connected to a hose for diversion to the temporary longitudinal drainage,
to sumps or longitudinal trenches in the bottom of the respective headings.
(4) In wet areas on the rock surface, water shall be collected by semi-circular pipe portions
(preferably from corrugated, soft-PVC pipes) which are fixed to the rock by quick setting
mortar or shotcrete and diverted to sumps or longitudinal trenches in the bottom of the
respective headings.
288
(5) Wet areas in the shotcrete lining shall be drilled open and treated as above (3) or (4).
Weep holes drilled through the shotcrete up to 1 m into the rock shall avoid the buildup of
excessive water pressure onto the shotcrete lining.
(6) In tunnels, constructed in permeable soil or highly fractured rock, ring drains with a
diameter of 40 mm minimum may be required to avoid the build-up of water pressure behind
the shotcrete lining.
(7) The CONTRACTOR shall ensure that the sumps installed are kept clean and the
drainage system maintained so that all water during the construction period is adequately
controlled.
4.8.14 Tunnel Maintenance
The CONTRACTOR shall be responsible for maintaining the completed underground

works throughout the construction and contract period. As part of this maintenance,
remedial work shall be carried out when repairs are required to the structural or other
systems or when grouting is required to stop water inflow.
(1) The CONTRACTOR shall monitor the tunnel support systems, and record any
damage to the support systems. If necessary, remedial action shall be taken with
temporary propping, including evacuating the area and posting warning signs accordingly.
(2) The CONTRACTOR shall without delay take whatever measures are necessary to repair
the support systems, and carry out the remedial work accordingly.
(3) The CONTRACTOR shall, in addition to monitoring the support system, carry out
regular maintenance of the underground works, including but not limited to light bulb
replacement, cleaning, water removal, water pipe maintenance, ventilation system
maintenance, and cable maintenance. Maintenance shall include all repair work required to
maintain all equipment in working order.
(4) Except otherwise mentioned in the BOQ or elsewhere, the cost of this shall be deemed
to have been included in the rate given and the uniform percentage quoted by the contractor.
4.8.15 Removal of Tunnel Support
The work includes the removal of completed ground support for the excavation of niches
and other enlargement of the tunnel. The CONTRACTOR shall submit Shop Drawings of
temporary supports and protective facilities for completed structures to the ENGINEER.
1) Before any tunnel support is removed, the location shall be pre-supported to prevent
tunnel lining from deformation, distortion or damage.
2) If necessary, ground stabilization or improvement shall be employed by the
CONTRACTOR to stabilize the ground.
289
This Clause does not apply to the removal of temporary support installed at the tunnel face
or at the top heading invert (shotcrete, wire mesh, face bolts).
4.8.16.1. Site Traffic on final Excavation level
(1) Final excavation levels (formation level) for pavement construction shall be protected
against any wear or deterioration of rock properties following site traffic by backfilling with
rock material excavated in the tunnel or similar to a minimum thickness of 0.5 meter.
(2) Ponding water and traffic through ponding water shall not be allowed.
(3) Any deteriorated material shall be removed and replaced prior to pavement works as
directed by the ENGINEER. The backfill material used for protection purposes shall be
removed in the main tunnel only until immediately prior to pavement construction works.
4.8.16.2. Site Traffic on Invert Support
No site traffic shall be allowed to run on unprotected invert structures, temporary or final,
concrete or shotcrete. Structures as such shall be protected against destruction by backfilling
with suitable excavation material from the tunnel or similar with a minimum thickness of
0.5 Meter. Backfilling material shall not contain boulders larger than 150 mm diameter.
4.8.16. 3. Tunnel Excavation through (potential) Karst Areas
During excavation of the tunnel in limestone, karst cavities and voids are expected to be
encountered which may be filled with soft ground materials and water and which will
influence rock mass behavior and tunnel stability.
Exploratory drillings in advance of the excavation face, vertical into the tunnel invert (after
excavation and installation of primary support) and, where required, also at the tunnel side
walls shall be performed to identify such karst features.
Encountered karst cavities and voids shall, depending on their location, size, shape and
condition (void or filled), be supported with shotcrete, wire mesh, rock bolts, as required
and backfilled with backfill material and/or grout, shotcrete or filling concrete to an extent
to achieve satisfactory stability of the karst cavity and the tunnel. To achieve the required
stability of the tunnel during construction and operational phase, the standard support
measures as described in the various rock classes may be subject to adjustments. Additional
support measures, like pipe roofs, advance ground improvement by grouting, etc. may be
required. The actually required support and ground treatment measures shall be proposed
by the CONTRACTOR for each single case of encountered karst feature and will be subject
of approval by the ENGINEER.
4.8.16.4. Exploratory Drillings (pilot drillings)
Exploratory drillings shall be carried out where, in the opinion of the ENGINEER, karst
features are anticipated. Number, location, direction, diameter and length of exploratory
290
drillings shall be as instructed by the ENGINEER according to actually encountered
geological conditions.
4.8.16.5. Exploratory drillings ahead of excavation face
Generally, four exploratory drillings shall be carried out from the top heading face with a
minimum length of 25 m. The overlap of consecutive drillings shall be minimum 10 m. The
orientation of exploratory drillings shall be:
1. horizontal drilling in the top heading centre (for this drilling, no overlap is required).
2. drilling in the tunnel centre line underneath the top heading crown with an upward angle
of 15°.
3. drillings, one on the right and one on the left hand side, with an angle of 15° side wards
and 10° upwards, or as instructed by the ENGINEER.
4.8.16.6. Vertical exploratory drillings
After excavation and installation of the primary support in the tunnel, systematical vertical
drilling in the tunnel invert with 6 m length shall be performed every 5 m, or as instructed
by the ENGINEER.
4.8.16.7. Exploratory drillings at side walls
Additionally, existing karst features at the side walls shall be identified during drilling of
bore holes for rock bolts. In areas where rock bolts are installed locally only (spot bolting),
two drillings per side wall with a length of 6 m each shall be performed every 5 m, or as
instructed by the ENGINEER.
4.8.16.8. Probe Hole
A probe hole, wherever required, shall be drilled ahead of the excavation face to determine
in advance the nature of the material/strata to be excavated and the presence of water and
gases.
In general, depending on the rock mass conditions 1 to 3 bore holes of Φ 76mm minimum
shall be executed at the top heading, without core-sampling, of length of 20m minimum and
30% overlapping, as follows:
One (1) probe hole in the tunnel center line underneath the top heading crown with an
upward angle of 10°.
Two (2) probe holes, one on the right and one on the left hand side, with an angle of 10 -
15° sidewards and 10° upwards, or as instructed by DDC and or approved by the Engineer.
291
The following data should be recorded and submitted to the Engineer:
1. Diameter and type of equipment
2. Location of probing
3. Support class
4. Drilling length
5. Drilling mean (water or air)
6. Velocity of drilling per meter
7. Velocity of rotation
8. Applied pressure
9. Air or water pressure
10. Colour of returned water
11. Water losses
12. Material description
If the probe hole indicates the presence of excessive water ahead of the excavation face, the
contractor shall take appropriate precautions to facilitate excavation. Similarly, the
contractor shall adopt suitable measures to deal with any gases or zones or weakened rock
which may be encountered. All measures deemed necessary by the contractor shall be
subject to approval by the Engineer-in-charge.
4.8.17 Dewatering and Drainage Measures
Depending on the amount of encountered water inflow from karst features adequate and
timely dewatering and drainage measures shall be performed. Where an ongoing constant
water inflow through the karst feature is identified adequate measures for dewatering and
drainage shall be installed, e.g. collecting the water inflow with plastic hoses connected to
the drainage system.
4.8.18 Excavation and Support
Generally, excavation works shall be carried out with increased caution by approaching a
karst zone or feature. When arriving close to the expected karst feature, additional
investigations may be required to check out location and size of the karst feature in detail.
While actually driving through the karst feature, excavation and support shall be adjusted to
actual conditions. For the case of soft ground or debris encountered in the tunnel roof
adequate support and ground treatment measures to ensure stability and safety during
excavation shall be implied as instructed by the ENGINEER. Such support measures may
be:
292
1. advance grouting.
2. Forepoling, if required by installing a pipe roof.
4.8.18.1. Backfilling and Support of Karst Features
a) Karst features intersected by tunnel excavation If karst features are intersected during
excavation of the tunnel, existing soft ground or debris fillings inside the karst cavities shall
be removed and replaced by grout, shotcrete or filling concrete according to stability
requirements as instructed by the ENGINEER.
Karst cavities below the tunnel invert shall be backfilled with backfill material,
backfilling concrete or shotcrete as applicable according to condition of karst cavity (size,

shape) and as instructed by the ENGINEER.
Large karst cavities shall be adequately supported by shotcrete, wire mesh and rock bolts as
required for stability and as instructed by the ENGINEER.
b) Karst features encountered by drilling
If karst features are encountered by exploratory drilling only, size and location have to be
investigated closer and have to be backfilled by grouting as required for stability and as
instructed by the ENGINEER.
c) Backfill Material and Filling Concrete
Backfill material for backfilling karst cavities below the tunnel invert shall consist of free-
draining material like gravel or boulders as approved by the ENGINEER. Filling concrete
shall be concrete grade M10 according to IS 456: 2000 (Reaffirmed 2011).
4.8.19 Disposal of Excavated Materials
a) Tunnel Muck Yard:
The slope of the muck dump shall be as 1V:2H. To increase the factor of safety of the
dumping muck yard a berm of 4m width is also proposed at interval of 6m height of the
muck yard.
1. Retaining wall
A retaining wall shall be constructed throughout the boundary of the muck yard.
The height of the wall should be 1m. This will insure the possible muck fall on the road and
will give extra cover to the toe erosion of the muck yard. The following are the cross
sectional design of retaining wall. The retaining wall may be constructed with random
rubble masonry.
1.The total height of the retaining wall = 1.4m.
293
2.The height of the wall above the ground level = 1m
3.The height of the wall below the ground level = 0.4m
4. The top width of the wall = 0.3m
5. Bottom width of the wall = 1m
The payment of this item shall be made as per relevant item of schedule. However, the above
dimensions can be varied as per the site requirement. In
locations approved by the ENGINEER, if the immediate placement at the final location is
not possible. The excavated material shall be dumped at the final disposal locations and may
require re-handling as directed by the ENGINEER.
c) Excavated materials which are not suitable for construction and those in excess of the
requirement for construction shall be disposed off in the waste disposal area. Disposal of all
material shall be such that it will not interfere with natural drainage and is as per the
regulations for environmental protection.
d) The CONTRACTOR shall ensure that no excavated materials are disposed off in the
streams or at locations, where in the opinion of the ENGINEER, these are liable to be
washed away by the floods.
-------------***-------------
294
SECTION 5
SPECIFICATION FOR
SURVEYING AND INVESTIGATION
2022-23
295
SECTION 5: SPECIFICATION FOR SURVEYING AND INVESTIGATION
5.1 DOUBLE LEVELLING BY USING AUTO LEVEL (Item No.SI 1)

Double levelling by using Auto level to connect Geodetic Trigonometrical
survey, bench mark and establishing permanent bench mark at Dam site at place along
the canal alignment, submergence and in command area etc complete, as directed.
(Excluding cost of B.M. structure)
5.1.2 Scope of work

Double levelling from GTS bench mark to the location (either existing
permanent structure or permanent bench mark structure especially constructed) shown
by engineer in charge in the area to be surveyed.

5.1.3.1 Instruments
Automatic level :- Allowable mean elevation error on inverted staff graduated
to 5mm division varies between +_ 0.5 to 0.8 mm Per Km of forward or
backward leveling or Theodolite (IS : 2976-1964) or total station (ISO : 17123-
5 : 2018 (en)), with all attachments.
Levelling Staff:- folding type 4 meter leveling staff confirming IS : 1779- 1961
(reaffirmed 2006) or the Inverted staff 3m in length or Aluminium staff of 4m
length may be used.
Steel Tapes:- Confirming to IS : 1270-1965
5.1.3.2 Applicable IS Codes, ISO Codes

The manufacturing, testing, Field procedures for testing of instrument &
surveying etc shall comply with all currently applicable statutes, regulations,
standards and Codes. In particular, the following standards, unless otherwise
specified herein, shall be referred. In all cases the latest revision of the Codes
shall be referred to. If requirements of this Specification conflict with the
requirements of the standards/Codes, this Specification shall govern.
IS : 2976-1964 Specifications for Optical Theodolite

(Reaffirmed 2006)
ISO 17123-5 : 2018(en) Optics and Optical Instruments - Field procedures for
testing geodetic and surveying instruments - Part 5 Total
Stations
IS : 1779- 1961 Specifications for 4-m Levelling Staff, Folding Type
(reaffirmed 2006)
IS : 1270- 1965 Metric Steel Tape Measure (winding Type)
1. The basic data/information viz. GTS bench mark value & location, no. of PBM’s &
their location to be established shall be supplied by the engineer-in-charge. The
surveyors shall have to establish the value of the PBM on constructed or existing
permanent structures.
296
2. Each PBM shall be numbered & the value of the same shall be painted on it.
Numbering and painting value of the permanent bench marks established.
3. The PBM No. & value shall be clearly visible.
4. levelling from GTS bench mark to the location
5. Preparing maintaining and handing over the bench mark record
5.1.5 Presentation
1. Tracing on polymers transparent tracing film with 5 blue prints of the map shall be
submitted to engineer-in-charge the presentation shall consist of following
2.Combine map (preferably on village may) showing PBM’s established on dam site,
submergence, command. Canal alignment, spillway, tail & approach channel etc.
3.All field looks of work.

All drawings, sketches, maps, plans to be submitted to the engineer-in- charge shall be
drawn on polyester transparent tracing film of approved quality as directed by
engineer-in-charge. It shall be drawn in permanent black ink. Lettering shall be
stenciled unless otherwise specified. Proper numbering system shall be followed for all
the drawings. Each such tracing shall be accompanied by a legitimate ammonia print
taken from the tracing.
For carrying out the above work , expenses for the material, stationary, survey
instruments, communication technical, staff etc. excluding labour cost shall be borned
by the department.

The length of double levelling for establishing PBM shall be measured up to two
decimals of a Kilometer on map & rechecked on site. The minimum of two will be
considered for payment.

100% payment shall be made on receipt of R.A. bill to be raised after satisfactory
complete of labour work, duly certified by engineer-in-charge.
----------***----------
297
5.2Block contour survey of 10m x 10m grid using Total Station (Item No.SI 2A)

Block contour survey of 10m x 10m grid (Not less than 121 raw data points
distributed uniformly over a Hector) for irrigation projects using digital state of art
Total Station, including transfer of entire data to computer system in different
georeferential layer/themes using features of standard plotting Softwares compatible
with canal irrigation system design Software packages including contour plotting at
specified interval and scale. The test print of the drawing shall be approved by
Engineer-in-charge and the same shall be delivered in a CD format as well as hard
copy in six numbers including one print on tracing paper, as directed.
5.2.2 Scope of work

1. To fix of bench mark with double levelling by carrying the PBM from dam
site to submergence area.
2. To fix and demarcate the grid of contour as specified in the area between FTL
and TBL + 2.00 m height by chain and compass survey.
3. To take levels at every grid points specified interval on grid of submergence
area. The interval should be reduced as per topographical requirement.
4. To prepare grid map of submergence area on separate sheet.
5. Standardized notations should be used on all drawings. These should be
initially got approved from the Executive Engineer. The format for drawings
(dimensions, lettering, lettering names plate etc.) should also be initially got
approved from the Executive Engineer.
6. Though design details have been supplied or referred to the consultant will be
responsible for design of a work able economic system. To achieve this he
may propose change in the specifications to the Executive Engineer. After
receiving approval any other details necessary may also be asked for the
consultant, if asked will have to justify both technically and economically any
the design and layout details suggested by him and if he is not able to do so,
shall have to accept changes suggested.
7. Entire data should be transferred to computer system in different
georeferential layer/ themes using features of standard plotting software’s
compatible with canal irrigation system design software packages including
contour plotting at specified interval and scale.
8. The test print of the drawing shall be approved by Engineer-in-charge and the
same shall be delivered in a CD format.
9. The circumstances arise which call for additions/ modification in the design
criteria the department shall intimate the additions/modifications to the
consultant. These additions/ modifications will have to be taken into account
in all works undertaken under the contract after they are intimated.
10. The data to be presented by Consultant or Contractor should be in following
format.
a) The consultant will have to submit the following document.

1. CD and Tracing of each map/ Hard disk
(Polymer transparent tracing film) 1 No
2. Computer print of each map 5 print each
3. All the alternative survey 5 copies
4. Reports 5 copies
5. Field books All
298
6. Grid map of submergence area 5 copies with
with 0.5 m interval Computerized
For carrying out the above work expenses for the material, stationary, labour, technical
staff survey instrument, transport charges, communication will be bearded by the
consultant.
a) All the drawing, sketches, maps, plans to be finally submitted to the department
should be drawn on polyester transparent tracing/film of approved quality as
directed by the Executive Engineer. They should be drawn in permanent black ink.
Lettering should be stencilled, unless otherwise specified and also inform of CD.
b) proper numbering system should be used. Each such tracing should be
accompanied by one legible ammonia print taken from the tracing.
c) All data should be neatly typed on good quality paper. Five copies should be
supplied.
5.2.3.1. Instruments
Total Station:-Confirming to ISO : 17123-5 : 2018 (en) with all attachments.
Lightweight, compact and streamlined Total Station-
Total station which Combines surveying, imaging and high-speed 3D scanning,
Scanning speeds of up to 26,600 Hz at ranges up to 600 m and the smallest spot
size - 14 mm at 100 m
Steel Tapes :- Confirming to IS : 1270-1965
5.2.3.2. Stationery
Tracing Film :- A0 Size Confirming to ISO : 5457 : 1980
5.2.3.3. Applicable IS Codes, ISO Codes
ISO 17123-5: 2018(en) Optics and Optical Instruments - Field procedures for
Stations
IS : 5457-1980 Technical Product documentation – Sizes and layout of
drawing sheets.

 The T.B.M. is to be fixed in the field of submergence area on the top of concrete
block C.C 1:2:4 of size 45x45x100 cm and embedded at centre.
 Any alternative survey carried by the consultant for deciding the economics
should be submitted.
 Submergence area mark on village map with detail of apex and bench mark.
 The scale on grid sheet map shall be ten times that of horizontal scale.
 carrying out survey of submergence area with grid 10m x 10m as specified
includes chaining compassing &levelling etc. complete.
 Plotting of above levels on village map & drawing the contour at 0.5 m interval.
 Supply of survey maps in the scale of 1:1000 & 1:4000 five copies each with one
mounted copy and tracing of all maps should be supplied.
 Providing and fixing apex point by header stones of sizes 20 cm x 15 cm x 45cm
which shall be fixed kin hard murum after necessary excavation. At least three
299
references permanent in nature should be given for every open point. The
reference permanent in nature should be given for every open point. The
reference number shall be painted on top of header stone. The header stone shall
project at least 10 cm above ground level. Location sketched of each apex point
so established shall be prepared. The list of all such apex with their notation’s
locations with reference to boundary line of survey numbers shall be separately
submitted.
5.2.4.1 Topographical Survey:
Establishment of Permanent Bench Mark:
 The irrigation department will furnish to be contractor details of GTS bench mark
with this as datum, a network of benchmarks one for every filed in submergence
should be established by the consultant with double levelling. These bench marks
should be suitably located on permanent holdings. The PBMs are required to be
constructed. The B.M will be checked by Department simultaneously as far as
possible but shall not be cause for lodging any claim if there is some delay on
this account.
 The consultant shall have to establish the value of the P.B. Ms constructed by
him from the bench mark value provided by Department. The values shall be
established by double levelling and provided by checking with in the P.B.Ms.
The permissible error shall not exceed the least count of the standard levelling
staves. The work of establishing the values of the PBMs shall be carried out in
advance of field work. In presence of representative of the Department not below
the Cadre of Junior Engineer.
 A proper system shall be evolved for numbering the PBMs. A plan (to scale of
1:1000 or 1:5000) indicating location and levels of all PBMs in the submergence
area be prepared and submitted to the Department for approval which will
normally be accorded within about 15 days.
 The grid map of submergence area shall be given the location of PBM with its
value written by oil paints.
 The PBMs shall be constructed by digging a pit the dimensions 450 mm x 450
mm x 1000 mm at a location which is not likely to be disturbed.
 The PBM should located at one corner of the field, which will not hamper during
agricultural operation and shall be 1 number per 20 Ha area.
 The pit shall be refilled by concrete 1:2:4 and the concrete top shall be about 75
mm above the ground level. Total depth of concrete block shall be 100 cm.
 Adequate care shall be taken by the consultant for curing of the concrete laid for
the PBM. The PBM shall be numbered in oil paints for its identification.
 The drawing for construction of PBM is attached. At least three permanent
references in nature should be given to every BM so fixed.
5.2.4.2 Other Levels:

 Any other level of the existing bench mark will be supplied to the consultants by
the department or are exhibited on drawing, pillars, etc. shall be checked by the
consultant with reference to the PBMs mentioned above and any discrepancy
shall be immediately brought to the notice of engineer-in-in charge. His decision
in this regard should be obtained in writing, before actual survey is commenced.
5.2.4.3 Survey:
 Submergence area survey be taken as the first activity of this work along with
carrying out the GTS bench mark. The starting point shall be given by the
department.
300
 The plan of submergence area shall be submitted for approval of Engineer-in-in
charge. He may suggest correction and modification as per requirement and
necessary. Such correction and modification shall be incorporated in the map
after necessary survey and final grid plan of submergence area shall be submitted
after security acceptance and approval from the competent authority. The survey
and planning of next work or its part shall be stated and completed as per above
said manner.
 After establishing a network of PBMs the actual grid survey should be
undertaken to obtain grid level as per specified interval with a properly located in
identifiable base line, sharp, local variations should be started from PBM and
shall have to be closed on PBM already fixed. Details of sketches for the survey
work under all items shall be drawn in field books. So that identification of any
detail seen the future if possible, to department. These field books shall be
handed over to the department.
5.2.4.4 Survey Maps: -

 After the above survey works is completed, sets of survey maps will be prepared
and submitted to a scale of 1:1000 indication the grid levels, and the contours at
1.50 m interval. The step should have sufficient overlap to enable simultaneous
study of area covered in two or more maps. An additional map to scale 1:4000 as
informed by Executive Engineer would also be supplied, indication all the area
under the grid of submergence at suitable intervals as informed by the Executive
Engineer.
 Copies of available maps will be supplied to the consultant by the department.
Relevant information from these maps will be superimposed by the consultant on
the maps prepared by him. Any major discrepancies between the village maps
and actual conditions of site will be immediately brought to the notice of the
Engineer- in- charge for his orders. The maps mentioned above will be submitted
to the Executive Engineer along with original field books and levels book. They
should not be used for further work till they are approved by department.

a) For this purpose, all the surveyed will be considered for payment. This area should
be between FTL to TBL + 2.00 m contours. This will be calculated as per length
and width of grid for the component will be cross checked by graph.
b) The surveyed area will be measured as for side from maps so submit this area will
be rechecked from revenue records. The minimum of the two will be taken as final
area for payment. The area put to tender for survey is approximate. However, the
area exceeding the tendered quantity shall not be surveyed without permission of
Measurement of Block contour survey is Per Ha.
The payment will be made on the hectar basis. The part payments shall be made as per
table 1.
Table -1 Revised as per Govt. Lr. No. CDA/ 1285@163619235/86/CADA Irrigation
Department Mantrayala Dt. 24/ 10/1986
Eligibility for payment
Consultant will be eligible for part payment on completion of different stages of work
for different items as indicated below.
Stage of work % Payment for which
consultant will be eligible
For Item no 105-110
301
A. Completion of survey and submission of 40%
drawing (i.e., village map etc.)
B. Submission of computerised gridSurvey 40%
map with contours and computation of
capacity table.
C. After completion of above A & B 20%
(After three months of completion)
----------***----------
302
5.3 Block contour survey of 10m x 10m grid using DGPS (Item No.SI 2B)

DGPS, including transfer of entire data to computer system in different georeferential
layer / themes using features of standard plotting Softwares compatible with canal
irrigation system design Software packages including contour plotting at specified
interval and scale. The test print of the drawing shall be approved by Engineer-in-
charge and the same shall be delivered in a CD format as well as hard copy in six
numbers including one print on tracing paper,as directed.
5.3.2 Scope of work

1. To fix of bench mark with double levelling by carrying the PBM from dam site to
submergence area.
2. To fix and demarcate the grid of contour as specified in the area between FTL and
TBL + 2.00 m height by chain and compass survey.
3. To take levels at every grid pointas specified intervalon grid of submergence area.
The interval should be reduced as per topographical requirement.
5. Standardized notations should be used on all drawings. These should be initially
got approved from the Executive Engineer. The format for drawings (dimensions,
lettering, lettering names plate etc.) should also be initially got approved from the
Executive Engineer.
responsible for design of a work able economic system. To achieve this he may
propose change in the specifications to the Executive Engineer. After receiving
approval any other details necessary may also be asked for the consultant, if asked
will have to justify both technically and economically any the design and layout
details suggested by him and if he is not able to do so, shall have to accept changes
suggested.
7. Entire data should be transferred to computer system in different georeferential
layer/ themes using features of standard plotting software’s compatible with canal
irrigation system design software packages including contour plotting at specified
interval and scale.
criteria the department shall intimate the additions/modifications to the consultant.
These additions/ modifications will have to be taken into account in all works
undertaken under the contract after they are intimated.
format.
The consultant will have to submit the following document.

4. Reports 5 copies
303
5. Field books All
7. Providing Dgps raw data in rinex format in CD/Hard disk.
8. Provide All data points in .CSV format in CD/Hard disk.
9. Provide Contours in AutoCAD format @ 0.5 metre to 3 metre, Topographical plan

in AutoCAD compatible format in CD/Hard disk.
staff survey instrument, transport charges, communication will be beared by the
consultant.
supplied.
5.3.3.1 Instruments/Equipments
Total station which Combines surveying, imaging and high-speed 3D scanning,
Scanning speeds of up to 26,600 Hz at ranges up to 600 m and the smallest spot size -
14 mm at 100 m
DISTANCE MEASUREMENT
Range with specified prisms Good conditions
1 With reflector sheet 5 cm x 5 cm (2 in x 2 in)
1", 2", 3", 5". . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 m to 270 m (4.9 ft to 886 ft) 5"
Winterized. . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 m to 300 m (4.9 ft to 984 ft)
With single prism 6.25 cm (2.5 in)
1", 2", 3", 5". . . . . . . . . . . . . . . . . . . . . . . 1.5 m to 3,000 m (4.9 ft to 9,843 ft) 5"
Winterized . . . . . . . . . . . . . . . . . . . . . 1.5 m to 5,000 m (4.9 ft to 16,404 ft)
Accuracy (Standard Deviation based on ISO 17123-4)
Prism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±(2+2 ppm ×D) mm
Reflectorless. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .±(3+2 ppm x D) mm
Total station Scannerwith dense 3D scan data at up to 26,600 Hz with high precision
over the full measurement range of up to 600 m. Which capture point cloud data and
then automatically register with survey workflow.
5.3.3.2 Stationery
Tracing Film:- A0 Size
ISO 5457-1980

304
so established shall be prepared. The list of all such apex with their notations
submitted.

this account.
 The consultant shall have to establish the value of the P.B.Ms constructed by him
from the bench mark value provided by Department. The values shall be
305
thedepartment or are exhibited on drawing, pillars, etc. shall be checked by the
shall be immediately brought to the notice of engineer-in-incharge.His decision
5.3.4.3 Survey:
department.
 The plan of submergence area shall be submitted for approval of Engineer-in-
charge. He may suggest correction and modification as per requirement and
said manner.
detail seen the future if possible to department. These field books shall be handed
over to the department.
5.3.4.4 Survey Maps :-
Engineer.
a) For this purpose all the surveyed will be considered for payment. This area
should be between FTL to TBL + 2.00 m contours. This will be calculated as per
length and width of grid for the component will be cross checked by graph.
b) The surveyed area will be measured as for side from maps so submit this area
will be rechecked from revenue records. The minimum of the two will be taken
as final area for payment. The area put to tender for survey is approximate.
However the area exceeding the tendered quantity shall not be surveyed without
permission of the Engineer-in-charge
c) Measurement of Block contour survey is Per Ha.
306
table 1.
Table -1
Revised as per Govt. Lr. No. CDA/ 1285@163619
235/86/CADA Irrigation Department
Mantrayala Dt. 24/ 10/1986
Stage of work % payment for which
For Item no 105-110
drawing (i.e. village map etc.)
capacity table.
----------***----------
307
5.4 Block contour survey of 15m x 15m grid using Total Station (Item No.SI 3A)

Block contour survey of 15 m x 15 m grid (Not less than 64 raw data points
specified interval and scale.The test print of the drawing shall be approved by
copy in six numbers including one print on tracing paper,as directed.
5.4.2 Scope of work

1. To fix of bench mark with double levelling by carrying the PBM from dam site
to submergence area.
3. To take levels at every grid pointas specified intervalon grid of submergence
approval any other details necessary may also be asked for the consultant, if
asked will have to justify both technically and economically any the design and
layout details suggested by him and if he is not able to do so, shall have to
accept changes suggested.
layer/ themes using features of standard plotting software’s compatible with
canal irrigation system design software packages including contour plotting at
specified interval and scale.
consultant. These additions/ modifications will have to be taken into account in
all works undertaken under the contract after they are intimated.
format.
11. The consultant will have to submit the following document.
308
4. Reports 5 copies
5. Field books All
consultant.
b) A proper numbering system should be used. Each such tracing should be
supplied.
5.4.3.1 Instruments
Total Station :-Confirming to ISO : 17123-5 : 2018 (en) with all attachments.
Total station which Combines surveying, imaging and high speed 3D scanning,

5.4.3.2 Stationery
Tracing Film :- A0 SizeConfirming to ISO : 5457 : 1980
Stations
drawing sheets.

 The T.B.M. is to be fixed in the field of submergence area on the top of
concrete block C.C 1:2:4 of size 45x45x100 cm and embedded at centre.
309
 Plotting of above levels on village map & drawing the contour at 0.5 m
interval.
 Supply of survey maps in the scale of 1:1000 & 1:4000 five copies each with
one mounted copy and tracing of all maps should be supplied.
 Providing and fixing apex point by header stones of sizes 20 cm x 15 cm x
45cm which shall be fixed kin hard murum after necessary excavation. At least
three references permanent in nature should be given for every open point. The
reference number shall be painted on top of header stone. The header stone
shall project at least 10 cm above ground level. Location sketched of each apex
point so established shall be prepared. The list of all such apex with their
notations locations with reference to boundary line of survey numbers shall be
separately submitted.
 Topographical Survey:
 Establishment of Permanent Bench Mark:
 The irrigation department will furnish to be contractor details of GTS bench
mark with this as datum, a network of benchmarks one for every filed in
submergence should be established by the consultant with double levelling.
These bench marks should be suitably located on permanent holdings. The
PBMs are required to be constructed. The B.M will be checked by Department
simultaneously as far as possible but shall not be cause for lodging any claim if
there is some delay on this account.
 The consultant shall have to establish the value of the P.B.Ms constructed by
him from the bench mark value provided by Department. The values shall be
advance of field work. In presence of representative of the Department not
below the Cadre of Junior Engineer.
1:1000 or 1:5000) indicating location and levels of all PBMs in the
submergence area be prepared and submitted to the Department for approval
which will normally be accorded within about 15 days.
 The PBM should located at one corner of the field, which will not hamper
during agricultural operation and shall be 1 number per 20 Ha area.
 Adequate care shall be taken by the consultant for curing of the concrete laid
for the PBM. The PBM shall be numbered in oil paints for its identification.

Any other level of the existing bench mark will be supplied to the consultants by
310
consultant with reference to the PBMs mentioned above and any discrepancy shall be
immediately brought to the notice of engineer-in-incharge.
His decision in this regard should be obtained in writing, before actual survey is
commenced.
5.4.4.2 Survey:
department.
incharge. He may suggest correction and modification as per requirement and
after necessary survey and final grid plan of submergence area shall be
submitted after security acceptance and approval from the competent authority.
The survey and planning of next work or its part shall be stated and completed
as per above said manner.
undertaken to obtain grid level as per specified interval with a properly located
in identifiable base line, sharp, local variations should be started from PBM and
shall have to be closed on PBM already fixed. Details of sketches for the
survey work under all items shall be drawn in field books. So that identification
of any detail seen the future if possible to department. These field books shall
be handed over to the department.
5.4.4.3 Survey Maps :-
 After the above survey works is completed, sets of survey maps will be
prepared and submitted to a scale of 1:1000 indication the grid levels, and the
contours at 1.50 m interval. The step should have sufficient overlap to enable
simultaneous study of area covered in two or more maps. An additional map to
scale 1:4000 as informed by Executive Engineer would also be supplied,
indication all the area under the grid of submergence at suitable intervals as
informed by the Executive Engineer.
Relevant information from these maps will be superimposed by the consultant
on the maps prepared by him. Any major discrepancies between the village
maps and actual conditions of site will be immediately brought to the notice of
the Engineer- in- charge for his orders. The maps mentioned above will be
submitted to the Executive Engineer along with original field books and levels
book. They should not be used for further work till they are approved by
department.
a) For this purpose all the surveyed will be considered for payment. This area should be
between FTL to TBL + 2.00 m contours. This will be calculated as per length and
width of grid for the component will be cross checked by graph.
b) The surveyed area will be measured as for side from maps so submit this area will be
rechecked from revenue records. The minimum of the two will be taken as final area
for payment. The area put to tender for survey is approximate. However the area
exceeding the tendered quantity shall not be surveyed without permission of the
Engineer-in-charge.
311

table 1.
Table -1
For Item no 105-110
capacity table.

----------***----------
312

Block contour survey of 15 m x 15 m grid (Not less than 64 raw data points
5.5.2 Scope of work

format.
4. Reports 5 copies
5. Field books All
313

consultant.
supplied.
14 mm at 100 m
1", 2", 3", 5". . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 m to 270 m (4.9 ft to 886 ft) 5"
1", 2", 3", 5". . . . . . . . . . . . . . . . . . . . . . . 1.5 m to 3,000 m (4.9 ft to 9,843 ft) 5"
Prism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±(2+2 ppm ×D) mm
5.5.3.2 Stationery
Tracing Film :- A0 Size

ISO 5457-1980

314
submitted.
this account.
Other Levels:
315
Survey:
department.
said manner.
Survey Maps :-
Engineer.

a) For this purpose all the surveyed will be considered for payment. This area
should be between FTL to TBL + 2.00 m contours. This will be calculated as
per length and width of grid for the component will be cross checked by graph.
b) The surveyed area will be measured as for side from maps so submit this area
will be rechecked from revenue records. The minimum of the two will be taken
as final area for payment. The area put to tender for survey is approximate.
However the area exceeding the tendered quantity shall not be surveyed without
permission of the Engineer-in-charge
d)
table 1.
Table -1
316
For Item no 105-110
capacity table.
----------***----------
317

Block contour survey of 20m x 20m grid (Not less than 36 raw data points distributed
uniformly over a Hector) for irrigation projects using digital state of art Total Station,
including transfer of entire data to computer system in different georeferential layer / themes
using features of standard plotting Softwares compatible with canal irrigation system design
Software packages including contour plotting at specified interval and scale. The test print of
the drawing shall be approved by Engineer-in-charge and the same shall be delivered in a CD
format as well as hard copy in six numbers including one print on tracing paper,as directed.
5.6.2 Scope of work

format.

4. Reports 5 copies
318
5. Field books All
consultant.
supplied.
5.6.3.1 Instruments

5.6.3.2 Stationery
Tracing Fi/lm :- A0 SizeConfirming to ISO : 5457 : 1980
ISO 17123-5 : Optics and Optical Instruments - Field procedures for

2018(en) testing geodetic and surveying instruments - Part 5 Total
Stations
drawing sheets.

 Any alternative survey carried by the consultant for deciding the economics should
be submitted.
319
references permanent in nature should be given for every open point. The reference
permanent in nature should be given for every open point. The reference number
shall be painted on top of header stone. The header stone shall project at least 10
cm above ground level. Location sketched of each apex point so established shall
be prepared. The list of all such apex with their notations locations with reference
to boundary line of survey numbers shall be separately submitted.
Topographical Survey:
possible but shall not be cause for lodging any claim if there is some delay on this
account.
established by double levelling and provided by checking with in the P.B.Ms. The
permissible error shall not exceed the least count of the standard levelling staves.
The work of establishing the values of the PBMs shall be carried out in advance of
field work. In presence of representative of the Department not below the Cadre of
Junior Engineer.
area be prepared and submitted to the Department for approval which will normally
be accorded within about 15 days.
 The PBMs shall be constructed by digging a pit the dimensions 450 mm x 450 mm
x 1000 mm at a location which is not likely to be disturbed.
Other Levels:
consultant with reference to the PBMs mentioned above and any discrepancy shall
be immediately brought to the notice of engineer-in-incharge.
 His decision in this regard should be obtained in writing, before actual survey is
commenced.
 Survey:
department.
320
necessary. Such correction and modification shall be incorporated in the map after
necessary survey and final grid plan of submergence area shall be submitted after
security acceptance and approval from the competent authority. The survey and
planning of next work or its part shall be stated and completed as per above said
manner.
 After establishing a network of PBMs the actual grid survey should be undertaken
to obtain grid level as per specified interval with a properly located in identifiable
base line, sharp, local variations should be started from PBM and shall have to be
closed on PBM already fixed. Details of sketches for the survey work under all
items shall be drawn in field books. So that identification of any detail seen the
future if possible to department. These field books shall be handed over to the
department.
 Survey Maps :-
Engineer.
the maps prepared by him. Any major discrepancies between the village maps and
actual conditions of site will be immediately brought to the notice of the Engineer-
in- charge for his orders. The maps mentioned above will be submitted to the
Executive Engineer along with original field books and levels book. They should
not be used for further work till they are approved by department.
Engineer-in-charge.

The payment will be made on the hectare basis. The part payments shall be made as per
table 1.
Table -1
Mantralaya Dt. 24/ 10/1986
For Item no 105-110
321
capacity table.

----------***----------
322

5.7.2 Scope of work

format.

4. Reports 5 copies
5. Field books All
323

consultant.
supplied.
14 mm at 100 m
1", 2", 3", 5". . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 m to 270 m (4.9 ft to 886 ft) 5"
1", 2", 3", 5". . . . . . . . . . . . . . . . . . . . . . . 1.5 m to 3,000 m (4.9 ft to 9,843 ft) 5"
Prism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±(2+2 ppm ×D) mm
5.7.3.2 Stationery

ISO 5457-1980
324
submitted.
this account.
325
Other Levels:
Survey:
department.
said manner.
Survey Maps :-
Engineer.
a) For this purpose all the surveyed will be considered for payment. This area should
area for payment. The area put to tender for survey is approximate. However the
326
table 1.
Table -1
For Item no 105-110
capacity table.
----------***----------
327
5.8 Block contour survey of 30m x 30m grid using Total Station(Item No.SI 5A)

specified interval and scale.The test print of the drawing shall be approved by
5.8.2 Scope of work

1. To fix of bench mark with double levelling by carrying the PBM from dam site to
submergence area.
2. To fix and demarcate the grid of contour as specified in the area between FTL and
TBL + 2.00 m height by chain and compass survey.
3. To take levels at every grid pointas specified intervalon grid of submergence area.
The interval should be reduced as per topographical requirement.
5. Standardized notations should be used on all drawings. These should be initially
got approved from the Executive Engineer. The format for drawings (dimensions,
lettering, lettering names plate etc.) should also be initially got approved from the
Executive Engineer.
approval any other details necessary may also be asked for the consultant, if asked
will have to justify both technically and economically any the design and layout
details suggested by him and if he is not able to do so, shall have to accept changes
suggested.
layer/ themes using features of standard plotting software’s compatible with canal
irrigation system design software packages including contour plotting at specified
interval and scale.
8. The test print of the drawing shall be approved by Engineer-in-charge and the same
shall be delivered in a CD format.
9. The circumstances arise which call for additions/ modification in the design criteria
the department shall intimate the additions/modifications to the consultant. These
additions/ modifications will have to be taken into account in all works undertaken
under the contract after they are intimated.
format.

4. Reports 5 copies
5. Field books All
328
consultant.
supplied.
5.8.3.1 Instruments

5.8.3.2 Stationery

Stations
drawing sheets.

 The T.B.M. is to be fixed in the field of submergence area on the top of
concrete block C.C 1:2:4 of size 45x45x100 cm and embedded at centre.
 Plotting of above levels on village map & drawing the contour at 0.5 m
interval.
 Supply of survey maps in the scale of 1:1000 & 1:4000 five copies each
with one mounted copy and tracing of all maps should be supplied.
329
 Providing and fixing apex point by header stones of sizes 20 cm x 15 cm x
45cm which shall be fixed kin hard murum after necessary excavation. At
least three references permanent in nature should be given for every open
point. The reference permanent in nature should be given for every open
point. The reference number shall be painted on top of header stone. The
header stone shall project at least 10 cm above ground level. Location
sketched of each apex point so established shall be prepared. The list of all
such apex with their notations locations with reference to boundary line of
survey numbers shall be separately submitted.
possible but shall not be cause for lodging any claim if there is some delay on this
account.
established by double levelling and provided by checking with in the P.B.Ms. The
permissible error shall not exceed the least count of the standard levelling staves.
The work of establishing the values of the PBMs shall be carried out in advance of
field work. In presence of representative of the Department not below the Cadre of
Junior Engineer.
area be prepared and submitted to the Department for approval which will normally
be accorded within about 15 days.
 The PBMs shall be constructed by digging a pit the dimensions 450 mm x 450 mm
x 1000 mm at a location which is not likely to be disturbed.
Other Levels:
consultant with reference to the PBMs mentioned above and any discrepancy shall
be immediately brought to the notice of engineer-in-incharge.
 His decision in this regard should be obtained in writing, before actual survey is
commenced.
 Survey:
department.
330
necessary. Such correction and modification shall be incorporated in the map after
necessary survey and final grid plan of submergence area shall be submitted after
security acceptance and approval from the competent authority. The survey and
planning of next work or its part shall be stated and completed as per above said
manner.
 After establishing a network of PBMs the actual grid survey should be undertaken
to obtain grid level as per specified interval with a properly located in identifiable
base line, sharp, local variations should be started from PBM and shall have to be
closed on PBM already fixed. Details of sketches for the survey work under all
items shall be drawn in field books. So that identification of any detail seen the
future if possible to department. These field books shall be handed over to the
department.
 Survey Maps :-
Engineer.
the maps prepared by him. Any major discrepancies between the village maps and
actual conditions of site will be immediately brought to the notice of the Engineer-
in- charge for his orders. The maps mentioned above will be submitted to the
Executive Engineer along with original field books and levels book. They should
not be used for further work till they are approved by department.
Engineer-in-charge.

table 1.
Table -1
For Item no 105-110
331
capacity table.
----------***----------
332

5.9.2 Scope of work

format.

4. Reports 5 copies
5. Field books All
333

consultant.
supplied.
14 mm at 100 m
1", 2", 3", 5". . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 m to 270 m (4.9 ft to 886 ft) 5"
1", 2", 3", 5". . . . . . . . . . . . . . . . . . . . . . . 1.5 m to 3,000 m (4.9 ft to 9,843 ft) 5"
Prism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±(2+2 ppm ×D) mm
5.9.3.2 Stationery

ISO 5457-1980

334
submitted.
this account.
Other Levels:
335
Survey:
department.
said manner.
Survey Maps :-
Engineer.

table 1.
Table -1
336

For Item no 105-110
D. Completion of survey and submission of 40%
E. Submission of computerised gridSurvey 40%
capacity table.
F. After completion of above A & B 20%
----------***----------
337

5.10.2 Scope of work

format.

4. Reports 5 copies
5. Field books All
338
consultant.
supplied.
5.10.3.1 Instruments
5.10.3.2 Stationery

Stations
drawing sheets.

339
submitted.
this account.
Other Levels:
Survey:Submergence area survey be taken as the first activity of this work along
with carrying out the GTS bench mark. The starting point shall be given by the
department.
340
said manner.
Survey Maps :-
Engineer.
Engineer-in-charge.
table 1.
Table -1
For Item no 105-110
341
D. Completion of survey and submission of 40%
E. Submission of computerised gridSurvey 40%
capacity table.
F. After completion of above A & B 20%

----------***----------
342
5.11 Block contour survey of 60m x 30m grid using Total Station (Item No.SI 6B)

layer/themes using features of standard plotting Softwares compatible with canal

format.

4. Reports 5 copies
5. Field books All
343

consultant.
supplied.
14 mm at 100 m
1", 2", 3", 5". . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 m to 270 m (4.9 ft to 886 ft) 5"
1", 2", 3", 5". . . . . . . . . . . . . . . . . . . . . . . 1.5 m to 3,000 m (4.9 ft to 9,843 ft) 5"
Prism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±(2+2 ppm ×D) mm
5.11.3.2 Stationery

ISO 5457-1980

344
submitted.
this account.
Other Levels:
345
Survey:
department.
said manner.
Survey Maps :-
Engineer.
table 1.
Table -1
346
For Item no 105-110
G. Completion of survey and submission of 40%
H. Submission of computerised gridSurvey 40%
capacity table.
I. After completion of above A & B 20%
----------***----------
347
5.12 Block contour survey of 150m x 30m grid using DGPS (Item No.SI 7A)


format.

4. Reports 5 copies
5. Field books All
348
consultant.
supplied.
5.12.3.2 Stationery


Stations
drawing sheets.

349
submitted.
this account.
Other Levels:
Survey:
350
department.
said manner.
Survey Maps :-
Engineer.
Engineer-in-charge.

table 1.
Table -1
351
For Item no 105-110
G. Completion of survey and submission of 40%
H. Submission of computerised gridSurvey 40%
capacity table.
I. After completion of above A & B 20%
----------***----------
352
layer/themes using features of standard plotting Softwares compatible with canal

format.

4. Reports 5 copies
5. Field books All
353

consultant.
supplied.
14 mm at 100 m
1", 2", 3", 5". . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 m to 270 m (4.9 ft to 886 ft) 5"
1", 2", 3", 5". . . . . . . . . . . . . . . . . . . . . . . 1.5 m to 3,000 m (4.9 ft to 9,843 ft) 5"
Prism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±(2+2 ppm ×D) mm
5.13.3.2 Stationery

ISO 5457-1980

354
submitted.
this account.
355
Other Levels:
Survey:
department.
said manner.
Survey Maps :-
Engineer.
356
table 1.
Table -1
For Item no 105-110
J. Completion of survey and submission of 40%
K. Submission of computerised gridSurvey 40%
capacity table.
L. After completion of above A & B 20%
----------***----------
357
5.14 Line survey using Total Station (Item No.SI 8)

Carrying out line survey with digital state of art Total Station for fixing
FRL/HFL including C/s survey with levels at 20m interval/ survey for 'L' section of
alternative Dam site and 'L' section of river 1Km u/s 1Km D/s of alternative Dam site
etc complete including station, including transfer of entire data to computer system in
different georeferential layer/themes using features of standard plotting Softwares
compatible with canal irrigation system design Softwares packages including contour
plotting at specified interval and scale. The test print of the drawing shall be approved
by Engineer-in-charge and the same shall be delivered in a CD format as well as hard
copy in six numbers including one print on tracing paper, as directed.
5.14.2 Scope of work:-

1. Plotting of above levels on village maps and drawing the contour at 20 m interval.
2. Supply of survey maps in the scale of 1:1000, 1:4000 five copies with one mounted
copy and tracing of all maps should be supplied.
3. Providing and fixing precast R.C.C. stone as apex stone directed by the Engineer
incharge. At least three references permanent in nature should be given for every
over point. The reference number shall be painted on top of stone established shall
be prepared.
4. The maps of canal needs to be submitted as per the “the note on compilation of
Govt. circulars and other on canal & canal structure”. This needs to be studied by
the Agency.
Total Station :- Confirming to ISO : 17123-5 : 2018 (en) with all attachments.
5.14.3.2 Stationery


Stations
drawing sheets.
358
1. Consultant / contractor will have to survey dam alignment. The contour map super
imposed on village shall be ready with the consultant / contractor.
2. The sill level of H.R. of dam, accordingly paper planning of dam alignment with
different alternatives should be worked out. Paper planning should be shown to
Executive Engineer. The tentative canal alignment on the basis of paper planning shall
be shown to E.E. and tentative consultant shall be obtained for this alignment for
further detailed survey.
3. Consultant / contractor will have to survey dam alignment for the alternative consulted
by the Executive Engineer. The survey includes L- sections of main canal by taking
levels at every 20 m interval c/s at every 90 m interval up to 150 m on either side.
Final alignment proposed is to be got approved from competent authority. 25% length
of dam alignment levels will be checked by sub divisional officer / Engineer & 2% by
the Executive Engineer.
4. Consultant / contractor should prepare area discharge statement cut off and C.B.L.
statement. The cut off and C.B.L. statement is to be got approved from competent
authority.
5. Any change should be suggested during the finalization shall be made good by the
consultant/contractor to the satisfaction of the concerned authority. Design parameters
of canal shall be adopted as per Govt. of Maharashtra Circulars No. MIS/1094/(156-
94) MPCA/ Dated :- 18/2/95 and subsequent modifications to it.
6. Kilo meter wise dam alignment with 150 m overlaps should be plotted with L-
sections and plan with contour & dam alignment map, with all details of survey &
design and drawings are submitted as directed by the Engineer Incharge.
7. Kilometerwise note on dam & river alignment containing detailed information of
canal,stratification and structures in that kilometers should be prepared for alignment
proposal.
8. For carrying out the above work expenses for the material stationary, labours,
technical staff, surveyinstrument, communication will be borne by the consultant /
contractor.
9. Consultant / contractor should submit the alignment proposal through proper channel
and get approval from appropriate competent authority. Any rectification suggested by
competent authority shall have to be carried out by consultant / contractor without any
extra payments.

Length of canal alignment as survey (with l/s & c/s) shall be measured up to decimals
of a kilometer on maps (by scale) and rechecked on site, the minimum of two be
considered for payment, on site , the minimum of two be considered for payment.
Measurement of Line Survey is Per Km.

The payment will be made on the basis of kilometer. 50% payment will be made on
submission of kilometer wise alignment proposal to the Division office, 40% payment
will be released after approval of alignment proposal from a competent authority.
Balance 10% will be released after submission of final approved detail reports &
drawing.
----------***----------
359
5.15 Survey of main canal, branches, distributaries using Total Station
(Item No.SI 9)

Survey for main canal, branches, distributaries with digital state of art Total
Station on falling contour including investigation of alternative line, taking falling
contour fixing canal line, taking 'L' section and cross section on final line and
distributaries survey including transfer of entire data to computer system in different
georeferential layer/ themes using features of standard plotting Softwares compatible
with canal irrigation system design Softwares packages including contour plotting at
specified interval and scale. Absolutely linear survey for all types of canals (Length of
survey for L-section and cross sections to be measured separately for payment) etc.
complete,as directed (Excluding fixing apex/chainage stones)

1. To fix up bench marks with double levelling by carring G.T.S bench marks from
given place to dam site. The T.B.M is to be fixed as under at every 0.5 K.M. of
main canal on the top of C.C. 1:2:4 block of size 0.45 x 0.45 x 1.00 m.
2. To make levels at every 20 m interval on L-section of main canal, distributaries.
The interval should be reduced as per topographical required.
3. To take cross sections at every 90 m interval on the main canal, branches and
minors and 150 m length on either side levels at 15 m interval.
4. To prepare map of L-section and c/s of main canal, branches, distributaries. The L-
section should be plotted for 1.00 Km length with 150 m long alignment of
previous K.M. and ongoing K.M. to know the topography on one sheet only.
5. The L-section should be represent bearing table. Details of apexes, details of
B.M., type and location of structures with their critical levels, schedule of structure,
L-section of each K.M. shall contain 200 m length of relevant, consequent and sub
sequent km.
6. Any alternative survey carried on by the consultant for deciding the economics,
should also be submitted.
7. Canal alignment marked on the village map, with details of apex, structures and
B.M.
8. The scales vertical scale on the L-sections shall be ten times that of horizontal
scale.

5.15.3.2 Stationery

360
Stations
drawing sheets.

1. Consultant / contractor will have to survey main canal alignment. The contour
map super imposed on village shall be ready with the consultant / contractor.
2. The sill level of H.R. of dam, accordingly paper planning of canal alignment
with different alternatives should be worked out. Paper planning should be
shown to Executive Engineer. The tentative canal alignment on the basis of
paper planning shall be shown to E.E. and tentative consultant shall be obtained
for this alignment for further detailed survey.
3. Consultant / contractor will have to survey main canal alignment for the
alternative consulted by the Executive Engineer. The survey includes L-
sections of main canal by taking levels at every 30 m interval c/s at every 90 m
interval up to 150 m on either side with levels at every 15 m interval additional
cross – sections near Nalla/streams, sudden change in topography, should be
taken if necessary. Final alignment proposed is to be got approved from
competent authority. 25% length of canal alignment levels will be checked by
sub divisional officer / Engineer & 2% by the Executive Engineer.
4. While surveying consultant / contractor should take details and location of
structures to be constructed on main canal, apex details with gate Nos. of fields,
wells with their distance from alignment with types, electric lines, and crossing
to main canal alignment & existing canal. If any temples, mosque, graveyards
with distances, roads with classification, alignment through garden, premises of
Public sentiments, graveyards should be avoided.
5. Consultant / contractor should prepare area discharge statement cut off and
C.B.L. statement. The cut off and C.B.L. statement is to be got approved from
6. Any charge should be suggested during the finalization shall be made good by
the consultant/contractor to the satisfaction of the concerned authority. Design
parameters of canal shall be adopted as per Govt. of Maharashtra Circulars No.
MIS/1094/(156- 94) MPCA/ Dated :- 18/2/95 and subsequent modifications to
it.
7. Kilo meter wise canal alignment with 150 m overlaps should be plotted with L-
sections and plan with contour & canal alignment map, with all details of
survey & design and drawings are submitted as directed by the Engineer
Incharge.
8. Kilometerwise note on canal alignment containing detailed information of
canal,stratification and structures in that kilometers should be prepared for
alignment proposal.
9. For carrying out the above work expenses for the material stationary, labours,
technical staff, surveyinstrument, communication will be borne by the
consultant / contractor.
10. Consultant / contractor should submit the alignment proposal through proper
channel and get approval from appropriate competent authority. Any
rectification suggested by competent authority shall have to be carried out by
consultant / contractor without any extra payments.
361
Length of canal alignment as survey (with l/s & c/s) shall be measured up to decimals
of a kilometer on maps (by scale) and rechecked on site, the minimum of two be
considered for payment, on site , the minimum of two be considered for payment.
Measurement of Line Survey is Per Km.

 The payment will be made on the basis of kilometer.
 50% payment will be made on submission of kilometer wise alignment proposal to
the Division office
 40% payment will be released after approval of alignment proposal from a
 Balance 10% will be released after submission of final approved detail reports&
drawing.
----------***----------
362
5.16 Preparation of detailed construction plan for PDN using Total Station
(Item No.SI 10A)

Preparation of detailed construction plan for pipe distribution network system
including necessary command survey, linear survey for pipe laying,chak planning,
designing of pipe network, and preparation of estimates,as directed.

 Block contour survey of required grid (Not less than 25 raw data points distributed
uniformly over 4 Hector) for irrigation projects using digital state of art Total
Station, including transfer of entire data to computer system in different
georeferential layer / themes using features of standard plotting softwares
compatible with canal irrigation system design softwares packages including
contour plotting at specified interval and scale.
 The test print of the drawing shall be approved by Engineer-in-charge & the same
shall delivered in a format as well as hard copy in six numbers including one print
on tracing paper,as directed.
 Preparation of detailed construction plan for pipe distribution network system.
 Chak planning, designing of pipe network, and preparation of estimates, as
directed.
5.16.3.2 Record
7/12 record of Land, Village maps.
5.16.3.3 Stationery

ISO 17123-5 : 2018(en) Optics and Optical Instruments - Field procedures for
Stations
PDN Handbbok WRD Maharashtra Pipe Distribution Network handbook
363
1. To fix of bench mark with double leveling by carrying the PBM from dam site to
submergence area.The T.B.M. is to be fixed in the field of submergence area on
the top an concrete block C.C 1:2:4 of size 45 x45 x 100 cm and embedded at
centre.To fix and demarcate the grid of 10 m x 10 m in the area of interest.To take
levels at every 10 x 10 m interval on grid of submergence area. The interval should
be reduced as per topographical requirement and prepare grid map of submergence
area on separate sheet.
2. To fix up bench marks with double levelling by carring G.T.S bench marks from
given place to dam site. The T.B.M is to be fixed as under at every 0.5 K.M. of
main canal on the top of C.C. 1:2:4 block of size 0.45 x 0.45 x 1.00 m.

The interval should be reduced as per topographical required.To take cross
sections at every 90 m interval on the main canal, branches and minors and 150 m
length on either side levels at 15 m interval.
4. To prepare map of L-section and c/s of main canal, branches, distributaries. The L-
section should be plotted for 1.00 Km length with 150 m long alignment of
previous K.M. and ongoing K.M. to know the topography on one sheet only.The
L-section should be represent bearing table. Details of apexes, details of B.M.,
type and location of structures with their critical levels, schedule of structure, L-
section of each K.M. shall contain 200 m length of relevant, consequent and sub
sequent km.
should also be submitted. Canal alignment marked on the village map, with details
of apex, structures and B.M. The scales vertical scale on the L-sections shall be ten
times that of horizontal scale. Submergence area survey be taken as the first
activity of this work along with carrying out the GTS bench mark. The starting
point shall be given by the department.
6. Conducting total station for generation of digital terrain model and block contours
at 0.5 metre to 3 metre intervals as per requirement
7. Total station should be 1 second accuracy. Data points should be picked up every
10 metres in undulating terrain and 25 metres in flat terrain. Establish sufficient
number of Ground Control Points in order to generate an accurate and seamless
view of the complete area.
8. Creating models of the dam seat , submergence , canal & command , approach,
tail channel, spillway and major infrastructure projects as per the Area of interest.
Preparation of complete Digitized map showing all the features like dam seat ,
364
submergence , main canal, branches, minors& command , approach, tail channel,
spillway and major infrastructure projects, etc.
9. Preparation Submergence area map mark on village map with detail of apex and
bench mark The scale on grid sheet map shall be ten times that of horizontal scale.
Providing and fixing apex point by header stones of sizes 20 cm x 15 cm x 45cm
reference permanent in nature should be given for every open point.
10. The reference number shall be painted on top of header stone. The header stone
shall project at least 10 cm above ground level. Location sketched of each apex
point so established shall be prepared. The list of all such apex with their notations
submitted. The plan of submergence area shall be submitted for approval of
Engineer – in –charge. He may suggest correction and modification as per
requirement and necessary. Such correction and modification shall be incorporated
in the map after necessary survey and final grid plan of submergence area shall be
submitted after security acceptance and approval from the competent authority.
12. Provide Digital terrain model in 0.5 metre resolution and grid spot level every 10
metres in CD/Hard disk.
13. Providing 5 set of contour map showing Contour Lines at every 0.5 metre to 3 as
per requirement of area of interest on scale of 1:1000 or 1:5000 and providing
capacity table of submergence.
14. Providing 5 set of Submergence area map mark on village map with detail of apex
and bench mark on scale of 1:1000 or 1:5000.
15. Providing 5 set of L-section of main canal, distributaries at every 20m. The
interval should be reduced as per topographical required.
16. Providing 5 set of cross sections at every 90 m interval on the main canal, branches
and minors and 150 m length on either side levels at 15 m interval.
17. Providing 5 set of map of L-section and c/s of main canal, branches, distributaries.
The L-section should be plotted for 1.00 Km length with 150 m long alignment of
previous K.M. and ongoing K.M. to know the topography on one sheet only.
18. Providing 5 set of Any alternative survey carried on by the consultant for deciding
the economics, should also be submitted.
365
19. Providing 5 set of plan of Canal alignment marked on the village map, with details
of apex, structures and B.M.
20. All the drawing, sketches, maps, plans to be finally submitted to the department
Lettering should be stencilled, unless otherwise specified and also inform of
CD/Hard Disk.
21. A proper numbering system should be used. Each such tracing should be
22. All data should be neatly typed on good quality paper and Five copies should be
supplied.

interval and scale.

Measurement of Block contour survey is Per Ha.

The payment will be made on the hectarage basis. The part payments shall be
made as per Table below.
Stage of work % payment for which consultant

will be eligible
A. Preliminary planning and designing of 50%
network & chak –plan, completion of
survey maps
B. On approval of detail plan of each 40%

chack
C. After final submission of chak – plans 10%

with detailed chak designed report
----------***----------
366
5.17 Preparation of detailed construction plan for PDN using DGPS
(Item No.SI 10B)

Preparation of detailed construction plan for pipe distribution network system
including necessary command survey, linear survey for pipe laying, chak planning,
designing of pipe network, and preparation of estimates,as directed.

 Block contour survey of required grid (Not less than 25 raw data points distributed
uniformly over 4 Hector) for irrigation projects using digital state of art DGPS,
including transfer of entire data to computer system in different georeferential
layer/themes using features of standard plotting softwares compatible with canal
irrigation system design softwares packages including contour plotting at specified
interval and scale.
 The test print of the drawing shall be approved by Engineer-in-charge & the same
shall delivered in a format as well as hard copy in six numbers including one print
on tracing paper as directed.
 Preparation of detailed construction plan for pipe distribution network system.
 Chak planning, designing of pipe network, and preparation of estimates, as
directed.
14 mm at 100 m
1", 2", 3", 5". . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 m to 270 m (4.9 ft to 886 ft) 5"
1", 2", 3", 5". . . . . . . . . . . . . . . . . . . . . . . 1.5 m to 3,000 m (4.9 ft to 9,843 ft) 5"
Prism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±(2+2 ppm ×D) mm
5.17.3.2 Record
7/12 record of Land, Village maps.
5.17.3.3 Stationery
ISO 5457-1980
367
1. To fix of bench mark with double leveling by carrying the PBM from dam site
to submergence area.The T.B.M. is to be fixed in the field of submergence
area on the top an concrete block C.C 1:2:4 of size 45 x45 x 100 cm and
embedded at centre.To fix and demarcate the grid of 10 m x 10 m in the area
of interest.To take levels at every 10 x 10 m interval on grid of submergence
area. The interval should be reduced as per topographical requirement and
prepare grid map of submergence area on separate sheet.
2. To fix up bench marks with double levelling by carring G.T.S bench marks
from given place to dam site. The T.B.M is to be fixed as under at every 0.5
K.M. of main canal on the top of C.C. 1:2:4 block of size 0.45 x 0.45 x 1.00 m.

The interval should be reduced as per topographical required.To take cross
sections at every 90 m interval on the main canal, branches and minors and
150 m length on either side levels at 15 m interval.
4. To prepare map of L-section and c/s of main canal, branches, distributaries. The
L-section should be plotted for 1.00 Km length with 150 m long alignment of
previous K.M. and ongoing K.M. to know the topography on one sheet
only.The L-section should be represent bearing table. Details of apexes, details
of B.M., type and location of structures with their critical levels, schedule of
structure, L-section of each K.M. shall contain 200 m length of relevant,
consequent and sub sequent km.
should also be submitted.Canal alignment marked on the village map, with
details of apex, structures and B.M.The scales vertical scale on the L-sections
shall be ten times that of horizontal scale.Submergence area survey be taken as
the first activity of this work along with carrying out the GTS bench mark. The
starting point shall be given by the department.
6. Dgps should be Real time kinematic GPS enabled to allow for accurate
measurement. generation of digital terrain model and block contours at 0.5
metre to 3 metre interval as per requirement.
7. Data points should be picked up every 10 metres in undulating terrain and 25

metres in flat terrain.Establish sufficient number of Ground Control Points in
order to generate an accurate and seamless view of the complete area.
8. Creating models of the dam seat , submergence , canal & command , approach,
tail channel, spillway and major infrastructure projects as per the Area of
interest.Preparation of complete Digitized map showing all the features like
368
dam seat , submergence , main canal, branches, minors& command , approach,
tail channel, spillway and major infrastructure projects, etc.
9. Preparation Submergence area map mark on village map with detail of apex
and bench markThe scale on grid sheet map shall be ten times that of
horizontal scale.Providing and fixing apex point by header stones of sizes 20
cm x 15 cm x 45cm which shall be fixed kin hard murum after necessary
excavation. At least three references permanent in nature should be given for
every open point. The reference permanent in nature should be given for every
open point.
10. The reference number shall be painted on top of header stone. The header
stone shall project at least 10 cm above ground level. Location sketched of
each apex point so established shall be prepared. The list of all such apex with
their notations locations with reference to boundary line of survey numbers
shall be separately submitted. The plan of submergence area shall be submitted
for approval of Engineer – in –charge. He may suggest correction and
modification as per requirement and necessary. Such correction and
modification shall be incorporated in the map after necessary survey and final
grid plan of submergence area shall be submitted after security acceptance and
approval from the competent authority.
13. Provide Contours in AutoCAD format @ 0.5 metre to 3 metre, Topographical

plan in AutoCAD compatible format in CD/Hard disk.
14. Provide Digital terrain model in 0.5 metre resolution and grid spot level every
10 metres in CD/Hard disk.
15. Providing 5 set of contour map showing Contour Lines at every 0.5 metre to 3
as per requirement of area of interest on scale of 1:1000 or 1:5000 and
providing capacity table of submergence.
16. Providing 5 set of Submergence area map mark on village map with detail of
apex and bench mark on scale of 1:1000 or 1:5000.
17. Providing 5 set of L-section of main canal, distributaries at every 20m. The
interval should be reduced as per topographical required.
18. Providing 5 set of cross sections at every 90 m interval on the main canal,
branches and minors and 150 m length on either side levels at 15 m interval.
369
19. Providing 5 set of map of L-section and c/s of main canal, branches,
distributaries. The L-section should be plotted for 1.00 Km length with 150 m
long alignment of previous K.M. and ongoing K.M. to know the topography
on one sheet only.
20. Providing 5 set of Any alternative survey carried on by the consultant for
deciding the economics, should also be submitted.
21. Providing 5 set of plan of Canal alignment marked on the village map, with
details of apex, structures and B.M.
22. All the drawing, sketches, maps, plans to be finally submitted to the
department should be drawn on polyester transparent tracing/film of approved
quality as directed by the Executive Engineer. They should be drawn in
permanent black ink. Lettering should be stencilled, unless otherwise specified
and also inform of CD/Hard Disk.
23. A proper numbering system should be used. Each such tracing should be
24. All data should be neatly typed on good quality paper and Five copies should
be supplied.
25. Entire data should be transfered to computer system in different georeferential

layer / themes using features of standard plotting Softwares compatible with
canal irrigation system design Software packages including contour plotting at
27. For carrying out the above work expenses for the material, stationary, labour,
technical staff survey instrument, transport charges, communication will be
borne by the consultant.
28. Providing 5 set of detailed construction plan for pipe distribution network
system.
29. Providing 5 set of Chak planning, designing of pipe network, and estimates, as
directed.

Measurement of Plan is Per Ha.

The payment will be made on the hectarage basis. The part payments shall be made as
per Table below.
370
Stage of work % payment for which consultant
will be eligible
A. Preliminary planning and designing of 50%

network & chak –plan, completion of
survey maps
B. On approval of detail plan of each 40%

chack
C. After final submission of chak – plans 10%

with detailed chak designed report
- ---------***----------
371
5.18 Providing permanent bench mark (Item No.SI 11)
Providing permanent bench mark dressed stone of basalt, granite or gneiss of
size 30cm X 30cm X 45cm at least 15Cm below the ground and embedding it to a
depth of 30cm in grade M-15 in-situ concrete of size 90cm X 90cm X 60cm deep over
1M deep foundation concrete of grade M-10 including excavation, concrete, providing
and fixing dressed stone and backfilling the pit up to ground level with sand etc.
complete, as directed.

 Excavation for Providing permanent bench mark dressed stone of basalt, granite or
gneiss of size 30cm X 30cm X 45cm
 grade M-15 in-situ concrete of size 90cm X 90cm X 60cm deep over 1M deep
foundation concrete of grade M-10
 backfilling the pit up to ground level with sand.
5.18.3Material Specifications
Shovel, Ghamela, Phawrah
5.18.3.2 Material
concrete of grade M-10, 30 x 30 x 45 cm stone
IS-456:2000

 To cast the blocks of required dimensions
 The stone (block) shall be of the dimensions 30cm X 30cm X 45cm. It should be
placed at least 15Cm below the ground and embedding it to a depth of 30cm in
grade M-15 insitu concrete of size 90cm X 90cm X 60cm deep over 1M deep
foundation.
 foundation concrete should be of grade M-10
 The blocks shall be fixed in position & places as indicated by the Engineer
Incharge.
 The side form shall be removed after 24 hours. The foundation shall be properly
cured for 21 days.

Measurement of Permanent Bench Mark is Per No.

The measurement shall be the number of such stone fixed in position at size and
payment is on per number basis.
----------***----------
372
5.19 Fixing precast RCC alignment blocks (Pillar) (Item No.SI 12)
Fixing precast RCC alignment blocks (Pillar) on alternative dam site finally
approved of size 900 x 175 x 100 mm at 90 M interval including fixing in 1:3:6 (600 x
450 x 450mm) cement concrete, excavation, backfilling and coloring etc. as directed.
(0.75 kg steel)

The item includes , excavation of pit for fixing 900 x 175 x 100 mm alignment blocks
of specified dimensions, as per drawing and as directed by the Engineer In charge.
Shovel, Ghamela, Phawrah
5.19.3.2 Material
Precast RCC block should be of 1:2:4 (40 MSA) concrete
IS-456:2000

1. The Pillars shall be of the dimensions 900 x 175 x 100 mm.
2. Proper shuttering shall be used to cast the blocks of required dimensions.
3. The blocks should be fixed in 1:3:6, in excavated pit of size 600 x 450 x 450mm
4. The side form shall be removed after 24 hours.
5. The blocks shall be fixed in position & places as indicated by the Engineer In
charge.

Measurement of Precast RCC alignment Block (Pillar) is Per No. The measurement
shall be the number of such blocks fixed in position at size and payment is on per
number basis.

The contract rate shall be for one block, fixed in position, on ground, mentioned in the
item
----------***----------
373
5.20 Supplying labour for Double levelling (Item No.SI 13)

Supplying labour for Double levelling to connect Geodetic Trigonometrical
Survey Bench Mark and establishing the Permanent Bench Mark at Dam site at place
along the canal alignment submergence and in command area etc.as directed.
(Excluding cost of P.B.M. structure)

Supplying labour for Double levelling to connect Geodetic Trigonometrical Survey
Bench Mark and establishing the Permanent Bench Mark at Dam site at place along the
canal alignment submergence and in command area etc.
5.20.3Material Specifications
Labour Supply

Supplying labour for Double levelling to connect Geodetic Trigonometrical Survey
Bench Mark
establishing the Permanent Bench Mark at Dam site
At place along the canal alignment submergence and in command area.

Measurement of Supply of Labours Per Km. The length of double levelling for
establishing PBM shall be measured up to two decimals of a Kilometers on map &
rechecked on site. The minimum of two will be considered for payment.

The length of double levelling for establishing PBM shall be measured up to two
decimals of a Kilometres on map & rechecked on site. The minimum of two will be
Payment shall be made on receipt of R.A. bill to be raised after satisfactory complete of
labour work, duly certified by engineer-in-charge.
----------***----------
374
5.21 Taking trial bore for detailed investigation with NX diamond drill
double tube (Item No. SI 14 A & 14 B)

Taking trial bore for detailed investigation with NX diamond drill double
tube in all sorts of soil like soft murum, hard murum and boulders including all
materials such as casing pipes, accessories, grease, steel boolsam and other such
materials and or as required including conveying such materials and machinery to site
of works, preserving the loose samples in glass/plastic jar and core samples serially
numbered at site of work and conveying the same to the head quarter of concerned
office as directed and submission of detailed bore log sheet etc. complete.(As directed
by the Engineer in charge)

1. Carrying out core drilling and supplying cores and samples in seasoned hard wood
box and glass jars with the log data.
2. Trial of the specified diameter shall be taken to the required depth to ascertain the
strata below ground level. The diameter of the bore refers to the diameter of the
core.
3. Compensation for any damage or injury during excavation of the item and rent etc,
for use of Private land shall be made good or compensated by the contractor.
4. Dewatering if any and necessary during the operation.
5. Conveying Erecting the boring machinery dismantling and removing the same after
completion.
6. All Labour, materials and use of equipment necessary to carry out in the item
satisfactorily
5.21.3.1Instruments/Equipments
Diamond drilling machine with NX bit type drilling ring may be used unless a
particular type of ring is specified in the special provisions. It shall be such as to
give core samples of the required diameter.
5.21.3.2 Material
-
IS:1892
1. The Contractor shall transport the necessary boring equipment to the site. The
equipment shall set up at predetermined location as directed by the
Engineer.Boring shall be done from ground levels to the required depth as
directed by the Engineer In the strata met with.
375
2. Carrying out core drilling and supplying cores and samples in seasoned hard
wood box and glass jars with the log data.
3. Only experienced operators who know proper handling of the machine careful
collection of the core and samples and correct logging of the operation shall be
employed.
4. Any water that will be met with shall be removed when necessarily either by
pumping or by any other method.Suitable casing pipes shall be provided
wherever necessary to prevent collapse of the sides.A permanent mark shall be
left to indicate the site of the bore.
5. The equipment shall be dismantled and removed from the site after boring is
completed.

Measurement of Trial Bore is Per Rmt.

1. The payment will be made on the depth per meter basis.
2. The payment will be paid after the equipment dismantled and removed from the
site (after completion of work) after satisfactorily submitting deliverables.
----------***----------
376
5.22 Providing core box of M.S. (Item No.SI 15)

Providing core box of M.S. of size 1.25m x 0.35m x 0.15m for preserving
core sample with all fixtures and fastening handles including locking arrangement etc.
Complete, as directed.
Core boxes shall be constructed of Metal Box with a lid having secure fastenings and
shall be to the acceptance of the Authorized representative appointed for supervision
by Engineer in charge.
5.22.3.1 Instruments/Equipment’s
Core Box of M.S. of size 1.25m x 0.35m x 0.15m
Core boxes shall be constructed of Metal Box with a lid having secure fastenings and
shall be to the acceptance of the Authorized representative appointed for supervision
by Engineer in charge
5.22.3.2 Material
Core Box of M.S. of size 1.25m x 0.35m x 0.15m

IS 1892- Code of practice for Subsurface Investigation for foundation
IS 4078 - Code of practice for Indexing and storage of dill cores
1. The core boxes should be usually 6Mtr capacity i.e 4 grooves of 1.5 M depth.
Width of each groove should be about 3.mm wider than the size of core to be
collected
2. The core boxes should be good workmanship. They should be study and durable as
records have to be maintained over long period. The boxes should be painted.
3. The core boxes filled with cores should be marked as follows (Top lid) (Inside of
lid)-
a. Project Drill Hole No
b. Site Location
c. Drill Hole Chainage
d. Box No. of Top R.L
8. All marking on boxes and core should be in black paint or on white background.
9. The core should be placed in the core box and loose strata sample soil, gravel, rock
may be kept in cloth bags (15 cm x 21 cm.) Writing the details on a bag in indelible
ink.
10. Mark the depth on every sizeable core piece paints an arrow on the core pieces to
indicate the direction of recovery of the cores.
11. Dummy round wooden pieces should be inserted in the box groves in portions
where no recovery is obtained. These pieces should also be painted of their depth
in natural location.
377
12. Core boxes should be arranged a vertical rock in a room and carefully reserved to
facilitate inspection at any time. They should be painted on top with the name of
the project and the Serial number of the box.
13. Rope strands shall be attached to the core box for lifting. Core boxes shall not
contain more than 50 kg of core.
14. The boxes are to be temporarily kept free from damage. If the sampled core is
damaged the Authorized representative appointed for supervision by Engineer in
charge shall instruct a new borehole to recommence.
15. The size of the core boxes should be 1.25 x 0.35 x 0.15m.
16. Core boxes should be labelled according to the boreholes assigned respectively.
17. Sample tubes containing soil samples shall be packed in suitable boxes with
compartments for each sample tube.
18. Each box should be provided with two lifting ropes or slits for handling.
19. All such boxes shall be labelled and transported to the laboratory within a week of
extraction. Preferably a laboratory can be established at site.
3.1 The contract rate shall be per core box supplied. The size of the core boxes should
be 1.25 x 0.35 x 0.15m.
3.2 Part rate will be paid for the boring in the upper strata, full rate for the same being
paid when the boring is carried to required depth and strata and all the cores and
samples with their logs are supplied to the Department.
3.3 The Core boxes will be measured for payment which are labelled according to the
boreholes assigned respectively.
3.4 For this purpose, no of boxes will be measured as per above conditions will be
3.5 However, the number exceeding the tendered quantity shall not be drilled without
permission of the Engineer- in –charge.
5.22.6. Mode of Payment

4.1 The payment will be made on the number of core boxes basis.
4.2 The payment will be paid after all such boxes labelled and transported to the
laboratory.
----------***----------
378
5.23 Carrying out water intake test/permeability test (Item No.SI 16)

Carrying out water intake test/permeability test at any stage or depth as may
be directed by Engineer in charge by filling the bore hole with water or air at specific
pressure of specified limit as and where directed. (Reference: P.W.D. Chapter-6, Page
71, B-Foundation Exploration).

Carrying out percolation test in hard strata at every 3.00m (10ft) interval as per
specification and directions inclusive arranging necessary equipment’s on-site work
etc. complete.
Percussion Drilling machine with double packer arrangement and 5 BHP of
water pump
5.23.3.2 Material
-
IS 2720-1986 Methods of test for soils
IS 5529-2013 In-situ Permeability test

1. The water intake or percolation test will be carried out by method known as
“Packer test.”
2. Rubble packers of suitable size having required elasticity shall be used.
3. The test shall be carried out after drilling the total depth required and conducting
the tests from bottom to top.
4. If any other procedure is to be followed the same should be got approved will in
advance from the Executive Engineer-in-charge of the work in writing.
5. The entire test shall be carried out only in presence of Engineer-in-charge or his
authorized representative.
6. Before starting the test, the depth of bore hole shall got finally approved from the
Engineer-in-charge of work.
7. Bore stating the test bore hole shall be filled with water for initial saturation for 2
to 4 hrs. and bore hole will be surged. The contractor shall not claim anything extra
for this work.
8. After each test, pipe is to be lifted by 1.5 meters. (5’) interval and test is repeated
until entire hard strata are tested.
379
9. The item also includes carrying out test in inter trapping layers if met with.
10. The test shall be carried out step by step with pressure of 0.25 H, 0.75H & 1.0 H
(Where H is the difference between the F.R.L. and the mean level of the test
section or the ground water level whichever is less of water head. Pressure being
increased in the order mentioned) or at such other pressure it may be directed by
the Engineer-in-charge or his representative.
11. The intake will be observed keeping pressure constant for a period not less than 10
minutes.
12. If desired by the Engineer-in-charge tests cycle will be carried for the pressure of
1.0H, 0.75, 0.25H (pressure being reduced in the order mentioned)
13. Item also included necessary retuning etc. without any extra cost.
14. The entire apparatus and the whole assembly shall be entirely leak proof of and
even if a slight leakage observed the apparatus shall be liable for rejection and no
claims shall be entertained.
15. Rate shall be inclusive of transport of machinery to site, errection, adjustment

dismantling and shifting to another place of test etc. including in the item rate.
Water required for operation of intake test completely is to be arranged by the
contactor without any extra charge.
16. Water loss in Lugeon shall be calculated and presented in register for every test.
17. {1 Lugeon = [average water loss in lit/ (time in minute X Depth)] X [10/ average
pressure]}

1. A set of observation for tested section a pocket of 3.00 mtrs. (Unless and
otherwise specified separately) will be tested, as one test will be measured
accordingly.
2. However, the number of tests exceeding the tendered quantity shall not be drilled
without permission of the Engineer- in –charge.

The payment will be made on the basis of number of tests conducted and Water
loss in Lugeon is presented in register.
----------***----------
380
5.24 Excavation for taking trial pits on final alignment of dam and canal
(Item No.SI 17)

Excavation for taking trial pits on final alignment of dam and canal at specified interval
and in Nalla bed of size 2.00 x 2.00 x 2.50mtr. in length, breadth and depth
respectively or size as may be directed by Engineer-In-charge including backfilling
trial pits etc. complete, as directed.

1. Furnishing all tools and plants, labour and material required for the work
throughout execution.
2. Providing quality assurance.
3. Line out of works, profiles etc. according to sanctioned plan or as directed by
Engineer-in-charge
4. Excavation to the designed section in dry or wet condition and removal of all
materials of whatever nature etc. use of tools, plants and equipments necessary
for satisfactory completion of the item
5. Refilling of Trial Pits. (Excluding watering and compaction charges).
6. Sorting out of useful excavated materials, conveying them clear beyond the work
area and stacking them neatly, depositing for use.
5.24.3. Material Specifications

JCB/Backhoe
5.24.3.2 Material
-
5.24.3 Applicable IS Codes, ISO Codes
IS 3764-1992 Excavation work-code of safety
1. All tools and plants, labour and material required for excavation work should be
arranged on site
2. Excavation of Trial pits on final alignment of dam and canal at specified interval and
in Nalla bed of size as directed by Engineer-In-charge
3. All the excavated material from excavation shall be selected properly by removing
bushes, roots, grass, other objectionable matter etc. and shall be sorted out into
different types of materials
4. If the excavated material is deposited in unauthorized land, such work shall not be
measured for payment unless suitable action as directed by the Engineer-in-charge is
taken by the contractor
5. All portion of excavation made for test pits or trial pits and all other existing cavities
found within the area is to be covered.

Trial pits should be measured in length, breadth and depth respectively or size as may
be directed by Engineer.
Measurement of Trial pits is Per Cum.
381
After complete excavation of trial pits and inspection of the Engineer in charge,
payment will be made on cubic meter basis and as per strata found.
----------***----------
382
For Office Use Only
SPECIFICATION FOR
SECTION : 06
HYDROMETEOROLOGY
2022-23
383
SPECIFICATION FOR HYDROMETEOROLOGY
6.1 Standard Rain Gauge Station (Measurement Clerk) (Item No. HD 01)
Specifications
Job responsibilities / - To take field observations at fixed time.
purpose - To make entry of data in the prescribed form.
- To dispatch the data to the controlling office daily.
Educational entry High School ( Matric)
requirements
Induction Basic Observers Course
training/experience
Tasks At stations with SRG only :
1. Measure rainfall at 08:30 hrs IST daily.
2. Enter the rainfall data in the prescribed form and also in the register.
3. Dispatch the rainfall data to controlling office as per prescribed
procedure.
Reporting / To report to controlling office (Sub-division) immediately if instrument
interactions becomes out of order or measure glass is broken.
Mode of Work will be measured and paid as per actual work done on monthly basis.
Measurement
6.2 Autographic Rain Gauge (Measurement Clerk ) ( Item No. HD 02 )
Specifications
Job responsibilities / - To take field observations at fixed time.
purpose - To make entry of data in the prescribed form.
- To dispatch the data to the controlling office daily.
Educational entry High School ( Matric )
requirements
Induction Basic Observers Course
training/experience
Tasks At stations with SRG only :
4. Measure rainfall at 08:30 hrs IST daily.
5. Enter the rainfall data in the prescribed form and also in the register.
6. Dispatch the rainfall data to controlling office as per prescribed
procedure.
At stations with both SRG & ARG, besides above tasks in respect of
SRG.
7. Remove the previous day chart and put the fresh chart on the clock
drum of the ARG at 0830 hrs IST.
8. To give time marks on the chart.
9. Tabulate hourly rainfall values from the autographic chart as per
proforma supplied.
10. Compare daily rainfall values of SRG & ARG.
11. Calculate monthly total of rainfall.
12. Dispatch periodic returns to controlling office (sub-division) as
prescribed.
13. Keep the instruments clean and in working condition.
14. Keep the observatory enclosure locked, clean and fencing intact.
15. Keep the exposure conditions good by clearing wild growths.
384
interactions becomes out of order or measure glass is broken.
Measurement
6.3 Full climatic station Measurement Clerk. ( Item No. HD 03)
Specifications
Job responsibilities / - Take field observations at Full Climate Station (FCS) at fixed times.
purpose - Make entry of data in the prescribed form.
- Remove the previous day charts and put charts on autographic
instruments.
- Process the data and dispatch to controlling office.
Educational entry - B.Sc. / Diploma in Engineering / Senior Secondary School with Science.
requirements
Induction Senior Observer Course
training/experience
Tasks 1. Record wind direction and wind speed.
2. Record rainfall (SRG).
3. Read dry and wet bulbs, read max. and min. temperatures
And set max. And min. thermometers and compare daily temperatures with
dry bulb temperature.
4. Measure pan evaporation.
5. Read barometer exact at 08:30 hrs IST if installed at FCS.
6. Make all observations in the above order 10 minutes before the
commencement of fixed hours of observations which are 08:30 and 17:30
hrs IST. (Start at 08:20 and 17:20 hrs IST).
7. Make entries of data in the prescribed forms in proper columns.
8. Remove the autographic charts of previous day of ARG, thermograph and
hygrograph and fix fresh charts with time mark.
9. Remove the previous autographic chart of sun-shine recorder (after sun set
only) and fix the fresh charts with time mark. (During rainy season, the fresh
chart is put next day before sunrise).
13. Tabulate / process the data from the autographic charts.
14. Compare eye - reading and autographic data.
15. Dispatch returns to controlling office as per prescribed time schedules.
16. Maintain eye - reading and autographic instruments in working
conditions.
17. Keep the observatory enclosure locked, clean and fencing intact.
18. Keep exposure conditions good by clearing wild growths.
interactions becomes out of order.
Measurement
6.4 Gauge Discharge (Gauge Inspector) (Item No. HD 04)
Specifications
His function Gauge reader
Job category / level Gauge reader
385
Job responsibilities To take observations of water level, rainfall, and temperature and take water
/ purpose samples at designated intervals and to assist the Station-in-Charge in the
velocity measurements, maintenance and operation of the gauging station
and meteorological station.
Educational entry Eighth grade standard
requirements
Induction training/ - Field Hydrometry and
experience - Placement of Instruments
Tasks 1. To observe and record water level on a staff gauge at designated intervals
over a specified period.
2. To note and record the occurrence of exceptional water levels within or
outside the designated period.
3. To keep gauge records secure and dry and to present them to senior
officers on request.
4. To check the operation of the Automatic Water Level Recorder (chart),
remove and annotate chart and replace.
5. To desilt stilling wells.
6. To carry out leveling surveys.
7. To carry out current meter gauging by wading, cableway bridge or boat.
8. To check the current meter.
9. To take float observations.
10. To take cross-sections of the river.
11. To take water samples for quality and suspended sediment testing, and
to take bed material samples.
12. To make rainfall and temperature observations (including changing
charts) at specified times and to specified standards.
Reporting / To Station-In-Charge
interactions
Measurement
6.5 Gauge Discharge Measurement Clerk. (Item No. HD 05)
Specifications
Job responsibilities To maintain a single primary gauging station or a specified network of stream
/ purpose flow gauging stations and rainfall/climate stations, and to ensure that reliable
and accurate data are collected, recorded and transmitted.
Educational entry Diploma in Civil Engineering / Degree in Science.
requirements
Induction Sufficient job experience and training in Principles of Hydrometry and Field
training/experience Hydrometry and Instrumentation
386
Tasks 1. To check gauge observations of the Hydrological Observer, to compile
records and transmit them to the Sub-Divisional Officer at frequencies
specified in the Manual.
2. To record in a Field Record Book any observed changes affecting station
performance as part of field checking.
3. To check the operation of the Automatic Water Level Recorder (chart,
logger, pressure transducer etc.), remove and note time and level details on
chart and replace; download and reset logger.
4. To install and arrange basic repairs and maintenance to staff gauges,
AWLRs, rainfall and climate equipment and arrange replacement of
consumables, demarcate discharge measuring cross-sections.
5. To supervise de-silting of stilling wells.
6. To carry out leveling surveys; compute and plot cross-sections and
longitudinal river sections.
7. To carry out / supervise current meter gauging by wading, cableway, bridge,
boat and flow measurements by floats.
8. To carry out vertical velocity distribution experiments.
9. To regularly compute and record on forms and registers discharge and
associated measures from current metering
And other measurements and return completed records to the Sub Divisional
Officer.
10. To carry out basic field maintenance of current meters including ratings,
counters, rods, winches, cables and fish weights, bridge and boat outfits, boat
anchorage, life-buoys, boat accessories, pumps etc.
11. To prepare graphical stage discharge and other relationships to understand
the characteristics of the river reach and any changes.
12. To carry out sampling and testing of water for suspended sediment and
water quality.
13. To supervise S-1and S-2 staff at the station or in the specified network.
interactions becomes out of order.
Measurement
6.6 Gauge Discharge (Boat Driver) (Item No. HD 06)
Specifications
Job responsibilities To assist the Station-In-Charge in the velocity measurements, maintenance and
/ purpose operation of the gauging station.
requirements
Induction training/ - Field Hydrometry, and
experience - Placement of Instruments
Tasks Do’s for Boatmen and Boat Drivers
1. Carry flotation devices
2. Carry life jackets
3.Communicate with passengers about safety measures
4. Proper maintenance of boat
5. Carry distress signal devices
6. Carry communication devices
387
7. Keep good look out for other boats and swimmers when in water
8. Store flammable item in a safe place
9. Carry fire extinguisher in a designated place Do’s for Passengers
10. Maintain the cleanliness of the site
11. Listen to the crew
12. Follow the rules
Do’s for Boat operator
13. Ensure the certificate of survey and license onboard when the boat is in
use
14. Ensure the crew is enough and sufficient to handle the passengers
15. Ensure that right information is circulated onboard
16. Ensure that boat is equipped and crew is trained to handle fire and rescue
passengers
17. Ensure that the boat is insured for third part risks
18. Ensure the boat is clean and dry while operating
19. Ensure proper communication mechanism exist before the boat starts
operating
Reporting / To Station-In-Charge
interactions
Measurement
6.7 Gauge Discharge (Boat Chowkidar) ( Item No. HD 07 )

Specifications
Job category / level Boat Chowkidar
Job category / level S-1
Job responsibilities / To assist the Station-in-Charge in the velocity measurements,
purpose maintenance and operation of the gauging station and meteorological
station.
requirements
requirements
Tasks 1. To clear silt, sediment and weeds in the river channel adjacent to the
gauges to maintain continuity of water level from the river to the gauges.
2. To check the operation of the Automatic Water Level Recorder (chart),
remove and annotate chart and replace.
3. To desilt stilling wells.
4. To assist with leveling surveys.
5. To assist with current meter gauging by wading, cableway, bridge or
boat.
6. To check the current meter.
7. To assist in float observations.
8. To take cross-sections of the river.
9. To take water samples for water quality and suspended
sediment concentration analysis and to take bed material
Samples.
388
10. Providing Boat Chowkidar (He must be good swimmer) to take care
& Security of boat. When the Water Level of river increase or decrease,
he must tighten the boat at safe place & taking care of boat in the night.
Reporting / interactions To Station-In-Charge.

Mode of Measurement Work will be measured and paid as per actual work done on monthly basis.
389
For Office Use Only
SECTION 8
SPECIFICATION FOR
FLOW MEASURING DEVICES
2022-2023
390
SPECIFICATIONS FOR FLOW MEASURING DEVICES
COMMON SPECIFICATIONS FOR FLOW MEASURING DEVICES
8.1) Item No. FMD 1:- GAUGE PLATE
8.1.1) Description of Item
Supplying gauge plate of FRP sheet, very sturdy both sides gelcoat finish composite
material, sandwich with M.S. strip by contact moulding process, engraved moulded bandwidth
and figures with computerised gauge marking with reflective radium pasting, spray lamination
with polyurethane chemical for surface protection including material required for fixing, nut
bolts, washers, Nylon rope, hanger, drilling machines etc. complete as directed.
8.1.2) Scope of Work
The items includes procurement of gauge plate getting it visually inspected for required shape
, dimensions, requisite coatings & marking before fixing the same in position at site.
8.1.3) Material specification
Gauge plate shall be of FRP sheet very sturdy both sides gelcoat finish composite material,
sandwich with M.S. strip by contact moulding process, engraved moulded bandwidth and
figures with computerised gauge marking with reflective radium pasting, spray lamination with
polyurethane chemical for surface protection including material required for fixing, nut bolts,
washers, Nylon rope, hanger, drilling machines.
8.1.4) Sequence of execution
The gauge plate shall be brought to work site as per specification and dimension. The surface
on which gauge plate is to be fix shall be cleaned and levelled of all irregularities. Plate shall
be installed and erected in correct line & level, drilling the holes and fixing the same with
washers, nuts bolts with the help of nylon roap and hanger.
8.1.5) Mode of Measurement

The measurement shall be in square meter. Actual length and breadth shall be consider for
measurement
8.1.6) Mode of Payment

Full payment shall be done after fixing gauze plates.
391
8.2 ) Item No. FMD 2 :- V - NOTCH
Providing, installing & erecting in correct line and level, fiber glass reinforced plastics (FRP)
“V Notch” of following sizes and discharge capacities, for accurate measurement of water
flowing through open channel with prefabricated fiber glass lining moulded engraved gauge
marking (in lit/ sec and in cms) including discharge table, capacity marking, flow direction,
sand treatment on the back side of “V” notch, testing, etc. complete as directed. (Excluding
base preparation in CBL, canal section and other concrete etc.)
The items includes procurement of V - Notch getting it visually inspected for required shape
, dimensions, requisite, coatings & marking before fixing the same in position at site.
V- Notch shall be fully moulded without joint ( As per IS 9108 :1979) of fiber glass reinforced
plastic ( FRP ) (CSM -450- 2 Nos. ) (Chopped strand mat imulsion grade E- glass type – density
450 gms/ sqm.) of requisite degree, overall plates size, V section and discharges, with
prefabricated fiber glass lining for accurate measurement of water flowing through open
channel with inside gelcoat finish ( Polyester gelcoat – polyester ISO NGO with UV grade )
moulded engraved gauge marking in lit / sec & in cms including capacity marking, flow
directing, sand treatment on the back site of V- Notch. V -Notch shall be engraved with
marking in centimetre with least count 2.5 mm. & in lit/ sec at one side and in cusec at another
side. Engraved portion shall fill with waterproof paints in dark colour. Moulded engraved
capacity marking showing cusec capacity of letter 2.5 cm. X 2.5 cm. and shall fill up with
waterproof paints in dark blue colour. Moulded arrow direction for flow from U/S to D/S shall
fill up with radium in dark colour. M.S. pipe stiffeners shall be embedded in FRP material as
per capacity of V – Notch.
Table Showing Dimensions For V - Notch As Per Is 9108: 1979
Se. Capacity Degree of V V- section in Cm Over all plate sizes

No. Notch in Cm
1 15 lit/ sec 53.6 22.5 X 26 25 X 39
2 15 lit/ sec 90 20 X 40 40 X 55
3 30 lit/ sec 90 25 X 50 50 X 65
392
No. Notch in Cm
4 45 lit/ sec 90 28 X 56 50 X 70
5 60 lit/ sec 90 30 X 60 50 X 75
6 90 lit/ sec 90 35 X 70 55 X 90
7 120 lit/ sec 90 42 X 84 60 X 100
Table Showing Reinforcement For V – Notch
Sr. No. Type & Capacity of V - Notch Reinforcement
V- NOTCH
a) 15 lit/sec. To 120 lit/sec. CSM-450- 2 Nos.
CSM – Chopped strand mat imulsion grade E- glass type – density 450 gms/m2
WR - Woven roving E glass type – density 600 gms/m2
Polyester gelcoat - Polyester ISO NGO with UV grade
Resin - Unsaturated polyester resin GP grade with retardants.
V- Notch shall be brought to work site as per specification and dimension. V - Notch shall be
installed and erected in correct line & level using 3 Nos. of M.S. pipe stiffeners for discharge
15 lit/ sec to 120 lit/ sec.
The Unit of item for measurement is number. The item will be measured as per supplied
numbers.
The payment shall be made on number basis. The supplier should carry out supply, installation
commissioning and testing of instrument. Before installation of instrument, instruments shall
be calibrated. Original calibration report should be produce with each instrument. The charges
of calibration will be paid by supplier.
393
8.3) Item No. FMD 3:- CTF
8.3.1) Description of Item.
cut throat flume (CTF) measuring devices on calculated hump level for accurate measurement
of water flowing through open channel with prefabricated fiber glass lining moulded engraved
gauge marking (in lit/ sec and in cms) including discharge table, capacity marking, flow
direction, sand treatment on the back side of flume, testing etc. complete as directed.
(Excluding CBL and hump preparation, canal section and other concrete required for hump U/S
and D/S slopes of hump etc.)
The items includes procurement of CTF, getting it, visually inspected for required discharge,
section, throat section, bell mouth, corner length, diver length, total length, engraved gauging
marks, discharge table, capacity marking, flow direction, sand treatment before fixing the same
in position at site.
CTF as per FAO 16/2 shall be of fiber glass reinforced (CSM- chopped strand mat imulsion
grade E - glass type – density 450 gms/ sqm.) with moulded engraved gauge plate in flume at
of U/S & D/S sides of throat for both sides with marking in centimetre with least count 2.5 mm.
And in lit/ sec at one side and in cusecs at another side. Engraved portion shall fill up with water
proof paints in dark colour. Moulded engraved capacity marking showing cusec capacity of
letter 2.5 cm. X 2.5 cm. and shall fill up with water proof paints in dark blue colour. Moulded
arrow direction for flow from u/s to D/s shall fill up with radium in dark colour. M.S. pipe
stiffeners shall be embedded in FRP material as per capacity of flume.
Table - DIMENSIONS OF CTF AS PER FAO 16/2

CAPACITY SECTION THROAT BELL CONVER DIVER TOTAL
SECTION MOUTH LENGTH LENGTH LENGTH
MIN-MAX MIN-MIX
IN CUSECS IN CUMECS Wx L W B L1 L2 l
0.05-2.0 0.001-0.056 10 X90 10 30 30 60 90
0.10-4.0 0.003-0.114 20 X90 20 40 30 60 90
0.15-6.0 0.005-0.172 30 X90 30 50 30 60 90
394
CAPACITY SECTION THROAT BELL CONVER DIVER TOTAL
SECTION MOUTH LENGTH LENGTH LENGTH
MIN-MAX MIN-MIX
0.25-20.0 0.007-0.576 40 X180 40 80 60 120 180
0.38-30.0 0.011-0.872 60 X180 60 100 60 120 180
0.42-50.0 0.012-1.423 60 X270 60 120 90 180 270
0.70-85.0 0.020-2.402 100 X270 100 160 90 180 270
TABLE SHOWING REINFORCEMENT FOR CTF
Sr. No. Type & Capacity of CTF Reinforcement
CUT THROAT FLUME
a) 0.3 to 0.5 CUSECS CSM-450- 2 Nos.
b) 1 to 4 cusecs CSM-450- 2 Nos.
c) 5 to 15 cusecs CSM-450- 3 Nos.
d) 18 to 50 cusecs CSM-450- 3 Nos. & WR-600-1 No.
e) 60 to 80 cusecs CSM-450- 3 Nos. & WR-600-2 No.
CTF shall be brought to work site as per specification and dimension. CTF shall be installed
and erected in correct line & level using the numbers of fasteners as shown in table
Discharges in cusec Nos. Of M.S. Pipe stiffeners
½ cusec to 6 cusec 3 Nos
8 cusec to 20 cusec 4
25 cusec to 80 cusec 5 Nos & 3 Nos longitudinal
395
numbers.
396
8.4) Item No. FMD 4:- PARSHALL FLUME
parshall flume on calculated hump level of following sizes and discharge capacities, for
accurate measurement of water flowing through open channel with prefabricated fiber glass
lining moulded engraved gauge marking ( in lit/ sec and in cms) including discharge table,
capacity marking, flow direction, sand treatment on the back side of flume, testing etc.
complete as directed.
(Excluding CBL and hump preparation, canal section and other concrete required for hump
U/S and D/S slopes of hump etc.)

The items includes procurement of Parshall Flume, getting it visually inspected for required
shape , dimensions, requisite, coatings & marking before fixing the same in position at site.

Parshall flume shall be prefabricated fiber glass lining for accurate measurement of water
flowing through open channel with inside gelcoat finish (Polyester gelcoat – polyester ISO
NGO with UV grade
PARSHALL FULME AS PER IS 14371: 1996
CAPACITY THROAT CONVERGENCE DIVERGENCE
IN IN WIDTH LENGTH DEPTH WIDTH LENGTH WIDTH LENGTH DEPTH
CUSECS CUMECS
MIN-MAX MIN-MAX W F N D B C G K
2.8-141 0.1-4.0 2.40 0.60 0.230 3.36 2.4 2.70 0.92 0.072
5.6-292 0.16-8.28 3.05 0.91 0.343 4.76 4.27 3.66 1.83 0.152
6.7-518 0.19-14.68 3.66 0.91 0.343 5.61 4.88 4.47 2.44 0.152
8.1-884 0.23-25.04 4.57 1.22 0.457 7.62 7.62 5.59 3.05 0.203
10.9-1340 0.31-37.97 6.10 1.83 0.686 9.14 7.62 7.32 3.66 0.305
13.4-1665 0.38-47.16 7.62 1.83 0.686 10.67 7.62 8.94 3.96 0.305
16.24-1989 0.46-56.33 9.14 1.83 0.686 12.31 7.93 10.57 4.27 0.305
21.18-2638 0.60-74.70 12.19 1.83 0.686 15.48 8.23 13.82 4.88 0.305
397
CAPACITY THROAT CONVERGENCE DIVERGENCE
IN IN WIDTH LENGTH DEPTH WIDTH LENGTH WIDTH LENGTH DEPTH
CUSECS CUMECS
26.48-3285 0.75-93.04 15.24 1.83 0.686 18.53 8.23 17.27 6.10 0.305
TABLE SHOWING REINFORCEMENT FOR PARSHALL FLUME
Sr. No. Type & Capacity of Flume Reinforcement
PARSHALL FLUME
a) 100 to 400 cusecs CSM-450- 4 Nos. & WR-600-2 Nos.
b) 500 to1500 cusecs CSM-450- 4 Nos. & WR-600-3 Nos.
c) 1750 to 3300 cusecs CSM-450- 5 Nos. & WR-600-3 Nos.
398
Parshall flume shall be installed and erected in correct line & level using M.S. Pipe stiffeners
at 30 cm for both direction. M.S. Hold fasts shall be given 9 Nos for 10 X 90, 12 Nos for 20 X
90, 18 Nos for 40 X 180 and 40 Nos. For 100 X 270 section & 100 Nos or more for Parshall
flume embedded in chemical with minimum length 15 to 20 cm.
Manufacturer’s EMBLAME showing name, address, capacity of flume job no. Etc complete
shall be moulded on flume and shall be fill up with dark blue colour.
Discharge table shall be given attached with flume and showing change in discharge for every
5 mm. Difference in head, calibration formulae for free flow and submerged flow condition,
values of constants. C.N. and submergence limit for different flow conditions, example showing
how to calculate hump etc. Complete with all technical information and provision of holdfast
to embed in concrete. Moulded & engraved marking shall fill up with water proof paints. Sand
treatment shall be given from the back side of flume.
numbers.
399
TABLE NO. III V NOTCH AS PER IS 9108 : 1979

No. Notch in Cm
1 15 lit/ sec 53.6 22.5 X 26 25 X 39
2 15 lit/ sec 90 20 X 40 40 X 55
3 30 lit/ sec 90 25 X 50 50 X 65
4 45 lit/ sec 90 28 X 56 50 X 70
5 60 lit/ sec 90 30 X 60 50 X 75
6 90 lit/ sec 90 35 X 70 55 X 90
7 120 lit/ sec 90 42 X 84 60 X 100
400
For Office Use Only
SPECIFICATION FOR
SECTION: 09
MARKING BLUE LINE & RED LINE
2022-23
401
SPECIFICATIONS FOR MARKING BLUE & LINE RED LINE
Introduction:-
Flood zones marking are important to ascertain likely inundation area in respect of Cities,
Towns and Villages along the river banks. The flood zone marking helps in preventing loss
of life, property and environment by regulating land usage in prohibitive and Restrictive
Zones. The marking of flood zones will also help in removal of encroachments to keep
required waterway clear for safe passage of floods. Guidelines about the zones and lines have
already been issued vide circular under reference. Now, to ensure uniform and standardized
procedure, the guidelines on marking of flood lines on digital maps and computation of
floods to be adopted.
Requirement:-
The Contractor shall conduct the Land Survey and all levels shall be with respect to the
Mean Sea Level as established by the Survey of India.
9.1 FIXING CONTROL POINTS BY DIFFERENTIAL GLOBAL

POSITION SYSTEM (DGPS) (Item No. BRL 01)
Fixing control points by Differential Global Position System (DGPS) instrument at

every One Km. along the both side of river including collection of necessary flood data
etc. complete including labour welfare cess, service tax, labour insurance and all
applicable taxes etc. complete as directed vide Technical circular of MERI Nashik No.
DSO/PB-4/1582 dated 16/11/2015.
9.1.2 Scope of work
Carrying GTS bench mark to site, from the nearest available GTS benchmark
(Contractor to find out the location and details of GTS benchmark & shall establish
sufficient no of reference bench marks at site for facilitating levels for purpose of
measurements etc.).
Item includes work of:
• Survey work must be carried out by Differential Global Positioning System (DGPS)
along with survey instruments like Total Station which will be helpful for GIS mapping
of flood zones, and also for accurate and fast completion of the work.
• For marking the Prohibitive Zone and Restrictive Zone on maps, ground survey of the
river stretches along with flood inundation areas shall be carried out.
• Cross sections at the following points may also be taken.
1) At confluence of every tributary with main river on the downstream side.
402
2) At location of bridges, weirs, other important structures.
3) At sudden change in vertical and horizontal slopes / falls, curves, bends etc.
4) District and Taluka boundaries.
• Accuracy of these flood lines/zones is of utmost importance. Geographic Information
System (GIS) mapping of these flood zones especially of highly populated cities along
the rivers shall be done, to facilitate the transfer of these lines on ground.
9.1.3 Temporary Bench Mark (TBM)
• The TBM’s shall be established by the contractor. It shall be founded on firm stratum
so as to ensure no settlement. Location of such TBM’s shall be finalized in consultation
with the Engineer in charge in advance and shall be always based on nearest permanent
benchmarks
• The TBM’s shall be established by double circuit leveling from the permanent
benchmark connected to the nearest authenticated GTS/ Survey of India Benchmark.
The Benchmark shall be established within 10 m from the boundary and at location to
be indicated by Engineer in charge. The number of such a TBM’s (of basalt, granite or
gneiss of size 30*30*45 cm at least 15cm below the ground and embedding it to a depth
of 30cm in grade M-15 in situ concrete of size 90cm*90cm*60cm deep over 1m deep
foundation concrete of M-10 including excavation, concrete, providing and fixing
dressed stone and backfilling the pit up to ground level with sand etc.) at the site shall
be determined in conjunction with the Engineer in charge.
9.1.4 Horizontal and Vertical Control
• Horizontal control and vertical control of the topographic survey being carried out shall
be with reference to the nearest GTS. Control pillars and benchmarks of the survey of
India. This GTS control pillars shall be the basis for the baseline on the site being
surveyed. The levels from such a benchmark shall be transferred to the site being
surveyed either on the permanent and firm featured or on a pillar as specified and
specially erected for the purpose.
• In case there exists control points at the site being surveyed or near the site, the same
shall be identified and a preliminary survey shall be carried out to check their
correctness. All such control points shall be identified and demarcated in the area plan.
• Horizontal control shall be fixed by either any or a combination of triangulation method
or closed traverse method as directed by the Engineer in charge. Accuracies of
measurement shall be as defined herein after. All angles shall be measured by
theodolite only. In case of the traverse method, distance between any two consecutive
traverse stations shall not exceed 100 m.
• The baseline shall first be conveniently defined at site by a series of control pillars
preferably along the axis of the dam. The length of the baseline shall be at least 100 m.
The baseline shall be the basis of an orthogonal co-ordinate system for the site. Hence
the baseline shall be oriented so as to run parallel to one of the prominent boundaries
of the site or its general orientation.
• The baseline shall then be established with respect to the GTS control point pillars.
403
• The bearing of the baseline shall be determined with respect to the magnetic North.
While determining the magnetic north, the contractor shall ensure a minimum
interference from external factors such as transmission lines, telephone lines,
significant metal objects etc. Any error due to such interference shall be rectified.
• Vertical control point shall be established by theodolite or level on all triangulation or
closed traverse stations. The vertical control shall be closed by returning the traverse
to the starting point.
9.1.5 Survey Equipments
• The contractor shall mobilize and use appropriate and adequate number of latest
precision instruments and equipment required for successful execution of work.
• The contractor shall ensure that all the equipment / instruments and measurement
devices are properly calibrated at the start of the work to reflect factual values. The
contractor shall present to the Engineer in charge, calibration certificates for the
equipments, traceable to national standards. If required by the Engineer in charge, the
contractor shall have the instruments and devices tested at an approved laboratory at
his own cost. The contractor shall submit the corresponding calibration reports to the
Engineer in charge before these instruments are used for the work. If the Engineer in
charge desires to witness the calibration test, the contractor shall arrange for the same.
• The Engineer in charge reserves the right to reject any instrument and debar its use for
this work, if the Engineer in charge finds the equipment defective or found wanting in
any manner. The contractor shall then immediately replace such instruments at his own
cost without hampering the progress of work. No extension of time will be granted on
this account
9.1.6 Personnel for the Land Survey and Drawing
• The survey shall be carried out under the direction and control of qualified land
surveyor.
• The contractor shall provide all the personal, suitably qualified, for the successful
execution of the work. It is essential that the survey party and all personnel involved in
the work of land survey shall have the appropriate qualification, specialized knowledge
and experience.
• The field work shall be carried out and supervised full time by qualified surveyors only.
Experienced draftsmen and personnel shall execute the drawings only on computer
using AutoCAD. A qualified and experienced surveyor shall prepare the report.
• Contractor of the work shall employ or consult an expert from hydrology and river
channel hydraulics to arrive at correct and accurate methods of computation of flood
lines by using advanced software’s like HEC-RAS or other.
9.1.7 Errors and accuracies
• The contractor shall be responsible for the correctness and accuracy of the work done.
If any error detected, even if such work is approved, the error shall be rectified by the
404
contractor at his own cost. The Engineer in charge may check the survey work during
the course of the survey for which contractor shall provide all the means required at his
own cost. However such checks shall not absolve the contractor of his responsibility
for the correctness and accuracy of the work.
• All levels shall be read accurate to the nearest 5mm.
• The errors for linear measurement shall not exceed 10 mm.
• The error in angular measurement shall not exceed six (6) seconds per stations.
• In any triangulation or traverse, the cumulative angular error shall not be more than
13/N seconds where N is the number of traverse stations. The probable error of
computed sides shall not exceed 1 in 5000.
• The closing error for leveling shall not exceed + (5 k) mm. where k is the distance of
the traverse in kilometers.
• The computation of flood level by using digitized obtains data of river cross section
and floods shall be accurate to the nearest 100 mm. Which shall be verified during nest
flood before finalizing the payments and tender.
9.1.8 Mode of Measurements
• The measurement shall be in Kilometer basis.

• Measurement of all survey work shall as indicated in Schedule B of the contract
document. The work covered shall be measured on computer by AutoCAD. Only the
area surveyed as per requirement of the Engineer in charge and limited to 50 m beyond
Red line will be payable only.
• The mode of payment made in following 5 phases, after computation on the basis of
item rate and limited to following percentage of total cost of work in each phase for
marking blue line red line works.
405
Phase Particulars Percentage
No
I Completion of all survey work and submission of 30%
computerized/AutoCAD data along with point 0.5 m.
contours, cross section and L-sections of river
II Details of all digitized data with river cross section, 20%
structures across the river, details of banks, properties and
geological and construction details on the bank up to
given boundary as directed by engineer in charge
III Computerized computation of 100 Years and 25 years 20%
flood lines by using advanced software’s like HEC-RAS
IV Marking of flood lines on structures, construction of flood 20%
pillars/plates and one year physical verification of floods
data and flood lines on site as computed by contractor
V After satisfactory completion of all works i.e. final 10%
preparation and verification of assessment sheet-12, field
books, panchnama books as directed by field officer. and
all drawings with soft and hard copies
• Payment includes labour welfare cess, service tax, labour insurance and all applicable
taxes etc.
406
9.2 Traverse Survey along river with cross section at 100 m.c/c(Item No.
BRL02 )
Traverse Survey along river with cross section at 100 m .c/c along river .The levels on
cross section shall be at every 30 m c/c beyond past locally observed flood line, using
Differential Global Position System (DGPS) instrument including labour,
transportation, using sounding by boat in river water in wet condition and transfer of
entire data to computer system in different geo referential layers/ themes using features
of standard plotting software computable with design software package including
contour plotting at required interval and at a scale and following deliverables etc. all
complete as directed vide Technical circular of MERI Nashik No.DSO/PB-4/1582 dated
16/11/2015..
A) For Rivers/Nalas in Dry condition
B) For River and Nalas with deep water and flowing condition
9.2.2 Scope of Work
• Carry out detailed block contour survey at 100 x 30 m grid as specified, including under
water surveys in the riverbed, whenever required.
Item includes work of
• For densely populated cities lying on the banks of river, the cross sections of the river
shall generally be taken at 100 m c/c along the river. The levels on cross section should
be taken at 30 m c/c up to 100 m beyond the past observed flood line. In places where
there is no habitation or development on banks of river, spacing of cross sections may
be suitably increased depending upon the terrain to be surveyed and accuracy required
as directed by Engineer in charge. However, cross sections should not be at more than
1000m c/c. Thus, there shall not be any need for grid survey. Cross sections at the
following points may also be taken.
1) At confluence of every tributary with main river on the downstream side.
2) At location of bridges, weirs, other important structures.
3) At sudden change in vertical and horizontal slopes/falls, curves, bends etc.
4) District and Taluka boundaries
• Carrying GTS bench mark to site, from the nearest available GTS benchmark
(Contractor to find out the location and details of GTS benchmark & shall establish
sufficient no of reference bench marks at site for facilitating levels for purpose of
measurements etc.).
• To establish Horizontal Ground Control Points including those defining the Baseline
and demarcate them by RPs within the area by Triangulation or Closed Traverse or
407
both based on the nearest GTS / Survey of India station. These Control Points shall
form the basis of the Site Triangulation Network.
• The contractor shall have to remove grass bushes and shrubs coming in the working area
coming under this contract and dispose it neatly. All requisite permission should be
required to be taken by the contractor from the concerns.
• The contractor shall have to carry out detailed block contour survey at 100 x 30 m grid
in ferry portion or in wet area by use of Echo sound unit & boat if required.
• The contractor shall have to carry out detailed block contour survey from the permanent
bench marks already establish in the working area coming under this contract with the
help of Total station or by any modern technology. The contractor shall have to intimate
Engineer in charge regarding the methodology using on site to execute this item. During
survey work, any sharp or local variations noticed in the area in between 100 x 30 m
grid, shall be covered as additional points, no separate payment will be made for this
work. The contractor shall have to submit raw data downloaded from Total Station for
cross checking. The block contour survey work carried out by the contractor shall be
confirmed and cross checked concurrently by competent authority not below rank of
Assistant Engineer Gr II / Sectional Engineer. The contractor shall have to maintain
survey field book & should submit in the form of soft & hard copy to Engineer in charge.
Any corrections / modifications suggested by Engineer in charge will have to be taken
into account, and to be corrected for all the items under taken in this contract.
• During survey work, physical details such as roads of all categories, all types of electric
lines, all types of structures, boundaries of villages shall be noted. The contractor shall
have to transfer this data on village maps along with the detailed block contour survey
at 100 x 30 m grid. The contour interval of block shall be1 m.
9.2.3 Spot levels
• Spot level shall be taken at notes of grid of size as specified. The grid shall essentially
be perpendicular and parallel to the established baseline. A linear grid shall be adopted
to represent all local features. All spot elevations shall be plotted in the field drawing.
Contours shall also be drawn in the field and their trend checked in situ with the general
ground profile and terrain.
9.2.4 Survey Equipments
• The contractor shall mobilize and use appropriate and adequate number of latest
precision instruments and equipments required for successful execution of work.
• The contractor shall ensure that all the equipment / instruments and measurement
devices are properly calibrated at the start of the work to reflect factual values. The
contractor shall present to the Engineer in charge, calibration certificates for the
equipments, traceable to national standards. If required by the Engineer in charge, the
contractor shall have the instruments and devices tested at an approved laboratory at his
own cost. The contractor shall submit the corresponding calibration reports to the
408
Engineer in charge before these instruments are used for the work. If the Engineer in
charge desires to witness the calibration test, the contractor shall arrange for the same.
• The Engineer in charge reserves the right to reject any instrument and debar its use for
this work, if the Engineer in charge finds the equipment defective or found wanting in
any manner. The contractor shall then immediately replace such instruments at his own
cost without hampering the progress of work. No extension of time will be granted on
this account
• The survey shall be carried out under the direction and control of qualified land
surveyor.
and experience.
Experienced draftsmen and personnel shall execute the drawings only on computer
using AutoCAD. A qualified and experienced surveyor shall prepare the report.
9.2.6 Errors and accuracies
• The contractor shall be responsible for the correctness and accuracy of the work done.
If any error detected, even if such work is approved, the error shall be rectified by the
contractor at his own cost. The Engineer in charge may check the survey work during
the course of the survey for which contractor shall provide all the means required at his
own cost. However such checks shall not absolve the contractor of his responsibility for
the correctness and accuracy of the work.
• All levels shall be read accurate to the nearest 5mm.
• The errors for linear measurement shall not exceed 10 mm.
• The error in angular measurement shall not exceed six (6) seconds per stations.
• In any triangulation or traverse, the cumulative angular error shall not be more than 13/N
seconds where N is the number of traverse stations. The probable error of computed
sides shall not exceed 1 in 5000.
• The closing error for leveling shall not exceed + (5 k) mm. where k is the distance of
the traverse in kilometers.
• The computations of flood level by using digitized obtain data of river cross section and
floods shall be accurate to the nearest 100 mm. This shall be verified during next flood
before finalizing the payments and tender.
9.2.7 Maintenance of records
409
• All book entry shall be made in ink in proper field and level book in accordance with
the standard practice. Any wrong entry shall be neatly stuck out and rewritten. All such
books shall be made available for inspection by Engineer in charge during any stage of
the survey. If in the opinion of the Engineer in charge the book entries are unsatisfactory,
he may order the survey work to be redone.
• The contractor shall submit calculations to establish the accuracy of the work done. Area
of the plot and such other calculations that may be necessary.
• All the field work sheets of plane table survey work, is carried out, shall be maintained
for submission of the Engineer in charge.
• Contractor shall submit a survey and computed level data in the form of hard copies and
soft copies to the Engineer in charge s and all such data shall remain property of
Government.
• The measurement shall be in hector basis.

No
410
• Payment includes labour welfare cess, service tax, labour insurance and all
applicable taxes etc.
411
9.3 Delivering Contour map of 0.50 m. contour interval (Item No. BRL 03)
Delivering Contour map of 0.50 m. contour interval by using standard software &
superimposing it on village map with scale1:5000 showing Prohibited line( Blue line) &
Restricted line (Red line) along with mapping of structures & other details etc. all
complete as directed vide Technical circular of MERI Nashik No. DSO/PB-4/1582 dated
16/11/2015.
9.3.2 Scope of work
• Delivering Contour map of 0.50 m. contour interval by using standard software &
superimposing it on village map with specified scale showing Prohibited line( Blue line)
& Restricted line (Red line) along with mapping of structures & other details etc.

• Preparation of digitize data of cross section of river, L-section of river, structures along
and across the river, as directed by engineer in charge.
• A digitized data and detailed survey work shall be the property of Engineer in charge and
contractor shall not sale this data or drawings to any other agency.
• Make all the digital data compatible to use for advanced software’s like HEC-RAS for
finalization of flood level confirming with manual method.
• The digitized Village maps which are available in 1:5000 scales or any suitable scale
shall be obtained from Director of Land Records along with certified hard copy. These
maps shall be joined together. On these maps, the prohibitive and Restrictive zones shall
be clearly marked with the help of Blue & Red lines, along with the cross sectional details
and levels etc. GIS mapping of the flood lines shall be done.
• The floods corresponding to prohibitive and restrictive zones have to be suitably plotted
on maps to indicate blue and red line along the river banks.
• To identify and mark on the Survey Drawings places of worship, tombs, relics of
archaeological importance, transmission lines and towers, telephone / telegraph lines and
poles, power and lighting poles, trenches, identified underground services and any other
structure, etc.

• The survey shall be carried out under the direction and control of qualified land surveyor.
and experience.
Experienced draftsmen and personnel shall execute the drawings only on computer using
AutoCAD. A qualified and experienced surveyor shall prepare the report.
412

• The measurement shall be hector basis.

No
• Payment includes labour welfare cess, service tax, labour insurance and all applicable
taxes etc.
413
9.4 Providing computerized detailed cross section drawings in two
copies
(Item No. BRL 04)

Providing computerized detailed cross section drawings in two copies at 100 m interval
with actual profile of river (levels at every 30m. distance along cross section) on A-3
size paper with scale 1cm = 15m or 1cm = 30m which is suitable as per site condition
showing 25 year return flood line (Blue line) and 100 years return flood line (Red line)
computed by software analysis and submission in the form of soft and hard copy as
directed by Engineer in charge. So as to use the data of above Item No.173 to 175 by
HEC-RAS Software. including submission of check print and getting approval of
Engineer in charge etc. all complete as directed vide Technical circular of MERI Nashik
No.DSO/PB-4/1582 dated 16/11/2015.
9.4.2 Scope of work
• Preparing computerized Auto cad drawing of cross section at 100 m interval with actual
profile of river (levels at every 30m. distance along cross section) from the block contour
survey work carried out by the contractor on A-3 of size or on size suggested by engineer
in charge.
• The contractor should submit draft print for checking of the Engineer in charge. Any
corrections / modifications suggested by Engineer in charge will have to be taken into
account, and to be corrected for all the items under taken in this contract.
• Necessary payment for the plans and other documents that will have to be procured from
respective departments will be made by the contractor.
9.4.3 Drawing/Maps and field records/ Soft copies
• The contractor shall initially produce check prints (hard copy) of all drawings for review
and comments of the Engineer in charge prior to proceeding with the final copies at no
extra cost to the Engineer in charge. All comments of the Engineer in charge shall be
incorporated onto the final drawings.
• The contractor shall submit 5 hard copies and 5 CD’s/5 pen drives containing all the
drawings. The cost of these additional drawings will not be payable to the contractor
separately.
• The contractor shall mention and acknowledge on all the drawings, index plans, all the
reference survey and other data used for the survey and for compilation of the drawings.
• All the drawings shall have their respective scale drawn upon them.
• Drawing name plates and drawing number shall be as directed by the Engineer in charge
only.
414
• All drawing submitted by the contractor shall be in A-3 standard size only or as directed
by Engineer In charge
• The contractor shall prepare all drawings and maps in AutoCAD release 14. All these
drawings prepared in AutoCAD shall have various layers as directed by the Engineer in
charge.
• The contractor shall submit all the field records, field books, calculation, plane table
survey sheets, check Prints as Marked upon by the Engineer in charge etc.
• It shall be noted that all the drawings, maps, records, of copies acceptor produced by the
contractor shall be the sole property of the Engineer in charge and the contractor shall
not use any of the details for any other work without the written approval of the Engineer
in charge.
• The measurement shall be on cross section wise.

No
415
416
9.5 Computation of Blue line and red line (Item No. BRL 05)
Computation of Blue line ( 25 Year return flood line ) and red line ( 100 year return
flood line ) by using HEC-RAS software including estimation of flood getting
approval of competent authority for the same giving all the precise necessary
input details into the software, viz. cross sectional and longitudinal features of the
stream, flow obstructions etc. including site validation & recalculation to the
satisfaction of Engineer In charge etc. all complete as directed vide Technical
circular of MERI Nashik No. DSO/PB-4/1582 dated 16/11/2015.
9.5.2 Scope of work
• Computation of Blue line ( 25 Year) and red line ( 100 year) by using HEC-RAS
software including estimation of flood getting approval of competent authority
for the same giving all the precise necessary input details into the software
• The flood corresponding to Prohibitive and Restrictive zones have to be suitably

plotted on Maps to indicate Blue and Red lines along the river banks.
• Channel routing of the floods corresponding to Prohibitive and Restrictive Zones
shall be done by Hydrologic Engineering Center. River Analysis system (HEC
RAS) or by using any other suitable software. HECRAS is a computer
Programme that models the hydraulics of water flow through natural rivers to aid
channel flow analysis and flood Plain determination. The output of HEC RAS
can be suitably GIS mapped.
• If towns / cities / villages are situated on river banks adjacent to any confluence,
adequate check regarding backwater effect on flood lines need to be exercised. In
case of rivers joining sea, effect of high tide shall be considered while deciding
Prohibitive/Restrictive zones/, lines. Similarly afflux due to construction in
waterway of river channel due to bridges / weirs / encroachments etc. shall also
be considered.
• Contractor shall run these given discharges through digitized river cross-sections
and L-sections by using necessary hydraulic conditions as approved by Engineer
in charge to derive at 100 Years and 25 Years flood lines at all cross-sections
• To establish temporary bench marks and flood levels on permanent structure
like bridges, buildings, temples, these shall be tied to the nearest authenticated
GTS / Survey of India Benchmark.
• All flood data like 100 Year flood discharge and 25 Year flood discharge and in
between discharges shall be calculated by the contractor as per norms and got
approved from Engineer In-charge.
• Estimation of flood and getting it approved from competent authority including
giving all the precise necessary input details to the software, viz. cross sectional
417
and longitudinal features of the stream, flow obstructions etc. including site
validation & recalculation to the satisfaction of Engineer in charges. Any
corrections / modifications suggested by Engineer in charge will have to be taken
into account, and to be corrected for all the items under taken in this contract.
• The manual on computation of floods for marking flood lines shall also be
referred for detailed methodology and further guidance. (Guidelines for marking
of prohibitive and restrictive zones)
• The measurement shall be on Kilometer basis.

document. The work covered shall be measured on computer by AutoCAD. Only
the area surveyed as per requirement of the Engineer in charge and limited to 50
m beyond Red line will be payable only.
• The mode of payment made in following 5 phases, after computation on the basis
of item rate and limited to following percentage of total cost of work in each phase
for marking blue line red line works.
No
418
9.6 Providing computerized detailed river alignment with contours
(Item No. BRL 06)
Providing computerized detailed river alignment with contours on A-1 size paper
with scale 1 cm equal to 15 m or 30m whichever is suitable as per site condition.
(one sheet for one Km. length of river) with contour at 0.50 m. interval including
marking 25 years return flood level (Blue line) & 100 years return flood level
(Red line) line & showing locations of bridges, KT Weirs & other permanent
structures on each drawing along and across the river as directed by Engineer in
Charge, including providing one color check print & six hard copies(color print)
with one soft copy etc. all complete as directed vide Technical circular of MERI
Nashik No. DSO/PB-4/1582 dated 16/11/2015.
9.6.2 Scope of work
• Preparing computerized Auto cad drawing of cross river alignment from the
block contour survey work carried out by the contractor on A-1 of size paper
with scale 1 cm equal to 15 m or 30m or on size suggested by engineer in charge.
• Identify and mark on the Survey Drawings locations of bridges, KT Weirs,

places of worship, tombs, relics of archaeological importance, transmission lines
and towers, telephone / telegraph lines and poles, power and lighting poles,
trenches, identified underground services and any other permanent structures on
each drawing along and across the river, etc.
• The contractor should submit draft print for checking to the Engineer in charge.
Any corrections / modifications suggested by Engineer in charge will have to be
taken into account, and to be corrected for all the items under taken in this
contract.
• Necessary payment for the plans and other documents will be made by the
contractor.
9.6.3 Drawing/Maps and field records/ Soft copies
• The contractor shall initially produce check prints (hard copy) of all drawings
for review and comments of the Engineer in charge prior to proceeding with the
final copies at no extra cost to the Engineer in charge. All comments of the
Engineer in charge shall be incorporated onto the final drawings.
• The contractor shall submit 6 hard copies and 5 CD’s containing all the
drawings. The cost of these additional drawings will not be payable to the
contractor separately.
419
• The contractor shall mention and acknowledge on all the drawings, index plans,
all the reference survey and other data used for the survey and for compilation
of the drawings.
• All the drawings shall have their respective scale drawn upon them.
• Drawing name plates and drawing number shall be as directed by the Engineer
in charge only.
• All drawing submitted by the contractor shall be in A-1 standard size only.
• The contractor shall prepare all drawings and maps in AutoCAD release 14. All
these drawings prepared in AutoCAD shall have various layers as directed by
the Engineer in charge.
• The contractor shall submit all the field records, field books, calculation, plane
table survey sheets, check Prints as Marked upon by the Engineer in charge etc.
• It shall be noted that all the drawings, maps, records, of copies acceptor produced
by the contractor shall be the sole property of the Engineer in charge and the
contractor shall not use any of the details for any other work without the written
approval of the Engineer in charge.
• The measurement shall be on sheet basis i.e. per cross section.

• The mode of payment made in following 5 phases, after computation on the basis
of item rate and limited to following percentage of total cost of work in each
phase for marking blue line red line works.
420
No
421
9.7 Marking of 25 years flood level (blue line) & 100 years flood
level (Red line) (Item No. BRL 07)
Marking of 25 years flood level (blue line) & 100 years flood level (Red line) on
permanent structures like Bridges, Temples & other permanent structures along
& across river including painting, lettering at every not less than 100 m. interval
& not more than 500 m. on both the banks of river, after the final approval of
flood level. As directed by engineer in charge etc. all complete as directed vide
Technical circular of MERI Nashik No. DSO/PB-4/1582 dated 16/11/2015.
9.7.2 Scope of work
• Marking of 25 years flood level (blue line) & 100 years flood level (Red line) on
permanent structures like Bridges, Temples & other permanent structures along
& across river
• The digitized Village maps which are available in 1:5000 scales or any suitable
scale shall be obtained from Director of Land Records along with certified hard
copy. These maps shall be joined together. On these maps, the prohibitive and
Restrictive zones shall be clearly marked with the help of Blue & Red lines,
along with the cross sectional details and levels etc. GIS mapping of the flood
lines shall be done.
• The Blue and Red lines must be marked on permanent and prominent features /
structures like public building, bridges, temples etc. along the river, so that these
markings could be used for reference.
• The marking on maps and on ground shall be cross checked by ground truth
verification.
• After verification maps shall be submitted to the Regional Chief Engineer for
sanction. The digitized maps should be published on web site.
• In future if any dispute arises, regarding flood lines marked on ground and that
on maps, the flood lines and levels thereof marked on approved maps will be
considered final and binding. And hence contractor shall take every precaution
while preparing the maps.
• Fix up level plates (size : 500 x 300 x 3 mm. ) for 100 Years and 25 Years flood
levels along the river on both the banks or the important structures and locations
as directed by Engineer-in-charge.
• The measurement shall be on number basis

422
• The mode of payment made in following 5 phases, after computation on the

basis of item rate and limited to following percentage of total cost of work in
each phase for marking blue line red line works.
No
computerized/AutoCAD data along with point 0.5
m. contours, cross section and L-sections of river
structures across the river, details of banks,
properties and geological and construction details
on the bank up to given boundary as directed by
engineer in charge
III Computerized computation of 100 Years and 25 20%
years flood lines by using advanced software’s like
HEC-RAS
IV Marking of flood lines on structures, construction 20%
of flood pillars/plates and one year physical
verification of floods data and flood lines on site as
computed by contractor
preparation and verification of assessment sheet-
12, field books, panchnama books as directed by
field officer. and all drawings with soft and hard
copies
423
For Office Use Only
SECTION : 10
SPECIFICATION FOR
LAND RECLAMATION AND SOIL SURVEY WORKS
2022-23
424
SECTION :10 SPECIFICATION FOR LAND RECLAMATION AND
SOIL SURVEY WORKS
10.1 COLLECTING AND FILLING SOIL SAMPLES IN PLASTIC BAG

(Item No.LR 1)

Collecting and filling soil samples in plastic bag of size (15X23cm) 200
gauge and cloth bag of size (18X 25 cm) with inside flap of 4 X 5 cm for
address tag and packing properly including cost of bags etc. complete. As
directed.

To understand the degree of salinity/ alkalinity, soil samples are collected for
laboratory tests. The following soil tests are conducted to understand the
degree of salinity/ alkalinity of agricultural lands.
2.1 Test to obtain pH value of soils.
2.2 Test to determine Electrical conductivity of soils
1. Record Data
Command Map, Base Map
2. Instruments
Steel Tapes: -Confirming to IS: 1270-1965, Wooden Peg of size 60 cm to
demarcate the stack, Pickaxe for breaking and prying, the axe for hoeing,
skimming, and chopping through roots, Spade to collect the soil sample,
Crowbar for removing two objects or to force apart two objects, Ghamela
to collect and transport samples, Dagger to remove excavated stuff
stickled to pickaxe.
3.Material
Soil Sample Bag- plastic bag of size (15X23cm) 200 gauge and cloth bag
of size (18X 25 cm)
4. Applicable IS Codes, ISO Codes
The manufacturing, testing, Field procedures for testing of instrument
shall comply with all currently applicable statutes, regulations, standards
and Codes. In particular, the following standards, unless otherwise
specified herein, shall be referred. In all cases the latest revision of the
Codes shall be referred to. If requirements of this Specification conflict
with the requirements of the standards/Codes, this Specification shall
govern.
425
LR Guidelines Soil Sample Bags.
chapter V Sub point
5.3.1 Para 5 to 7,
page no.40

1. For damage demarcation in the affected survey number / gut number firs
auger bore is taken in the centre and soil samples at depths 0 to 20 cm, 20 to
40 cm, 40 to 80 cm, and 80 to 120 cm depths are to be collected.
2. At the time of taking auger pits the soil samples at the depth from 0 to 20
cm. 20 to 40 cm., 40 to 80 cm. & 80 to 120 cm. will be kept around the pit in
cyclic order at clockwise direction so as it is easy to sampling in plastic bag
of size (15 x 23 cm) 200 gauge.
3.And these plastic bags are packed in cloth bags of size (18 x 25 cm) with
inside flap of 4 x 5 cm for address tag & packing properly.

Measurement of Collecting & Filling Soil Sample is Per Auger hole.

100 % Payment is made through Running account bill.
----------***----------
426
10.2 TAKING WELL OBSERVATIONS IN THE COMMAND AREA
(Item No. LR 2)

Taking well observations in the command area including collecting data of
well water level, taking photos of wells for GPS Based Monitoring, with
Software developing, Maintenance of Web & Producing reports,
Synchronisation of reloads through Internet. & Cloud storage, Water samples,
visual observation of crops and preparing data base recording in well
observation book collecting water samples, Etc. complete as directed.

1 This item includes taking well observations during post monsoon as well as during
pre-monsoon every periodical year.
2 During Post-monsoonNovember December & January water levels of all wells in
the command have to be taken. Smartphone/Tablet mounted Global Positioning
System (GPS) is used to locate the exact position of the well along with the Latitude
and Longitude.

1.Record Data
Command Map, Village map
2. Instruments
Steel Tapes :- Confirming to IS : 1270-1965, GPS enabled devices.
3. Material
Wooden Peg, Soil Sample Bag, Pickaxe, Spade, Crowbar, Ghamela, Dagger
4. Applicable IS Codes, ISO Codes

The manufacturing, testing, Field procedures for testing of instrument shall
comply with all currently applicable statutes, regulations, standards and Codes.
In particular, the following standards, unless otherwise specified herein, shall
be referred. In all cases the latest revision of the Codes shall be referred to. If
requirements of this Specification conflict with the requirements of the
standards/Codes, this Specification shall govern.
LR guidelines Taking Well Observations.
chapter III Sub
point 3.2.1 , page
no.13-14
427
1. Water level in the well from GL will be measured with measuring tape. Taking
photographs of the well and synchronizing it and sending it to Irrigation Research
Division, Pune through internet will be done.
2. Filling up all the mandatory fields of the well observation application and then
submitting it to the server.
3. Synchronizing work will be done on the same day as per as possible. Observed
Gut Number wise data will be filled in well observation registers kept in sub
division. Gut Number wise and village wise detailed data statement will have to
be submitted to sub division office before 15th February. Data statement include
well water level from GL and approx. area of crops being irrigated on that
particular well.

Measurement of Taking Well Observations is Per No. of observed well.

----------***----------
428
10.3 TAKING AUGER BORES OF 10 CM. DIA. WITH AUGER (Item No. LR
3)

Taking auger bores of 10 cm. dia. with auger for classifying strata including
putting the excavated stuff in cyclic order, dewatering for recuperating results
etc. complete. As directed.(Augur Karkoon Not Engaged Departmentally)

This work includes Berma pits for Water logged area & taking Auger Pits for
Saline area.
1.Berma Pits- During Post Monsoon i.e. November, December & January every
year. Berma pits will have to be taken in Water logged areas as per instructions of
the Engineer-in-Charge. The depth of Berma pits will be 2.1 m. or Water level met
whichever is earlier should be taken.
2.Auger Pits- During Pre-Monsoon i.e. April, may of every year. These Auger pits
will have to be taken within salt affected area as per instructions of the Engineer-in-
Charge. The depth of auger pits will be 1.2 m. or hard murum met whichever is
earlier should be taken. At the time of taking auger pits the soil samples at the depth
from 0 to 20 cm.20 to 40 cm., 40 to 80 cm. & 80 to 120 cm. will be kept around the
pit in cyclic order at clockwise direction so as it is easy to sampling in plastic bag.
3.Normal Pits- These Normal pits will have to be taken on periphery of salt affected
area as per instructions of the Engineer-in-Charge. The depth of auger pits will be
0.4 m. or hard murum met whichever is earlier should be taken. At the time of
taking auger pits the soil samples at the depth from 0 to 20 cm.20 to 40 cm.& will be
kept around the pit in cyclic order at clockwise direction so as it is easy to sampling
in plastic bag.
For the above specified works Auger Karkoon Not Engaged Departmentally.

1. Record Data
Command Map, Village Map.
2. Instruments
Steel Tapes :- Confirming to IS : 1270-1965, Auger Bore of size 6 inch diameter, T-
shaped joint, Extension Rod up to 2 m.
3.Material
Wooden Peg, Soil Sample Bag, Pickaxe, Spade, Crowbar, Ghamela, Dagger
4.Applicable IS Codes, ISO Codes

The manufacturing, testing, Field procedures for testing of instrument shall comply
with all currently applicable statutes, regulations, standards and Codes. In
particular, the following standards, unless otherwise specified herein, shall be
referred. In all cases the latest revision of the Codes shall be referred to. If
429
standards/Codes, this Specification shall govern.
TP-56 Para 46 page Auger Bore
no.20
1 Berma pits will have to be taken in Water logged areas as per instructions of the
Engineer-in-Charge. The depth of Berma pits will be 2.1 m. or Water level met
2. The depth of auger pits will be 1.2 m. or hard murum met whichever is earlier
should be taken. At the time of taking auger pits the soil samples at the depth
from 0 to 20 cm.20 to 40 cm., 40 to 80 cm. & 80 to 120 cm. will be kept
around the pit in cyclic order at clockwise direction so as it is easy to
sampling in plastic bag.
3. The depth of auger pits will be 0.4 m. or hard murum met whichever is earlier
from 0 to 20 cm.20 to 40 cm.& will be kept around the pit in cyclic order at
clockwise direction so as it is easy to sampling in plastic bag.

Measurement of Taking auger bore is Per Running meter of Pit taken.
10.3.6 Mode of Payment+

---------***----------
430
10.4 TAKING AUGER BORES OF 10 CM.DIA.WITH AUGER (Item No. LR
4)

Taking auger bores of 10 cm.dia.with auger for classifying strata including
putting the excavated stuff in cyclic order, dewatering for recuperating
results etc. complete. As directed. (Augur Karkoon Engaged
Departmentally)

This work includes Berma pits for Water logged area & taking Auger Pits for
Saline area.
1. Berma Pits- During Post Monsoon i.e. November, December & January every
year. Berma pits will have to be taken in Water logged areas as per
instructions of the Engineer-in-Charge. The depth of Berma pits will be 2.1
m. or Water level met whichever is earlier should be taken.
2. Auger Pits- During Pre-Monsoon i.e. April, may of every year. These Auger
pits will have to be taken within salt affected area as per instructions of the
Engineer-in-Charge. The depth of auger pits will be 1.2 m. or hard murum
met whichever is earlier should be taken. At the time of taking auger pits the
soil samples at the depth from 0 to 20 cm.20 to 40 cm., 40 to 80 cm. & 80 to
120 cm. will be kept around the pit in cyclic order at clockwise direction so as
it is easy to sampling in plastic bag.
3. Normal Pits- These Normal pits will have to be taken on periphery of salt
affected area as per instructions of the Engineer-in-Charge. The depth of
auger pits will be 0.4 m. or hard murum met whichever is earlier should be
taken. At the time of taking auger pits the soil samples at the depth from 0 to
20 cm.20 to 40 cm.& will be kept around the pit in cyclic order at clockwise
direction so as it is easy to sampling in plastic bag.
For the above specified works Auger Karkoon Engaged Departmentally.

1 Record Data
2 Instruments
Steel Tapes :- Confirming to IS : 1270-1965, Auger Bore of size 6
inch diameter, T-shaped joint, Extension Rod up to 2 m.
3 Material
Wooden Peg, Soil Sample Bag, Pickaxe, Spade, Crowbar, Ghamela,
Dagger
4 Applicable IS Codes, ISO Codes
shall comply with all currently applicable statutes, regulations,
standards and Codes. In particular, the following standards, unless
otherwise specified herein, shall be referred. In all cases the latest
revision of the Codes shall be referred to. If requirements of this
Specification conflict with the requirements of the standards/Codes,
this Specification shall govern.
431
TP-56 Para 46 page Auger Bore
no.20

1 Berma pits will have to be taken in Water logged areas as per instructions of the
Engineer-in-Charge. The depth of Berma pits will be 2.1 m. or Water level met
2 The depth of auger pits will be 1.2 m. or hard murum met whichever is earlier
should be taken. At the time of taking auger pits the soil samples at the depth from 0
to 20 cm.20 to 40 cm., 40 to 80 cm. & 80 to 120 cm. will be kept around the pit in
cyclic order at clockwise direction so as it is easy to sampling in plastic bag.
3 The depth of auger pits will be 0.4 m. or hard murum met whichever is earlier
from 0 to 20 cm.20 to 40 cm.& will be kept around the pit in cyclic order at
clockwise direction so as it is easy to sampling in plastic bag.

Measurement of Taking auger bore is Per Running meter of Pit taken.
10.4.6 Mode of Payment+

----------***----------
432
10.5 MEASURING DRAIN DISCHARGE (Item No. LR 5)

Measuring drain discharge in every season including transporting and
installing temporarily the measuring device such as “V “notch on site with all
labour & material etc. recording in well observation book etc.complete. As
directed.

This work includes measuring drain discharge.
1 The contract rates shall be per soil sample. The rates shall be same to
all soil samples.
2 With help of “V” Notch supplied by the office the drain discharge
should be measured in rabbi season and kharif season of every year.
3 Discharge of each and every completed drainage scheme should be
measured.
4 Measurement of discharge should be done towards starting point of
main drain or towards end of outfall.
5 The collected information will be submitted to section office
immediately.
1 Record Data
Command Map, Village Map, Schematic plan of Drainage Scheme.
2 Measuring Device
“V” Notch:-Confirming to IS : 14750-2000, Fitting Assembly etc.
3 Material
Not Applicable
CODE OF PRACTICE FOR INSTALLATION,

IS : 14750-2000 MAINTENANCE AND OBSERVATION OF SEEPAGE
MEASURING DEVICES – V Notch.
1 The assembly of the 90° V notch is set up at the start of the drainage
scheme.
2 The head of the water at the measured at the face of the V notch and
the head available at the time of the measurements is put into the
standard formula given as per IS : 14750-2000.
433
Measurement of Drain Discharge is Per No. of Drains.
----------***----------
434
10.6 COLLECTING & FILLING WATER SAMPLES IN PLASTIC
BOTTLES (Item No. LR 6)

Collecting & filling water samples in plastic bottles including cost of plastic
bottles etc. complete. As directed.

This work includes Collecting & Filling water samples in plastic bottles.
1 During Post-monsoon i.e. November, December & January water levels of
all wells
in the command have to be taken.
2 Water level in the well from GL will be measured with measuring tape.
Wells having water level within 2.00 m, the water samples are collected for
every 0-2.00m well for testing of pH.

1 Record Data
2 Instruments / Devices
Beakers, Containers & pH-meter Confirming to IS : 2711-1979
3 Material
Distilled Water, water bottles.
IS : 2711-1979 Specification for pH meter.

Reference: as per Quality diagnosis of Irrigation water through wells.
LR guidelines
chapter IV, page
no.23 to 29

These collected samples are tested for EC and pH as per the following
procedure:
1 Testing Procedure for pH
(1) Take 20 ml of water into a beaker. Add 50 ml of distilled water &
stir with a glass rod throughly for about 5 minutes & keep an hour.
435
(2) Dip the electrodes in the beakers containing the water suspension
with constant stirring.
(3) While recording pH, switch the pH meter to pH reading, wait for 30
seconds & record the pH value to the nearest 0.1 unit. Put the pH
meter in standby mode immediately after recording.
(4) Remove the electrodes from water& clean the electrodes with
distilled water.
(5) Rinse the electrodes after each determination & carefully blot them
dry with filter paper before the next determination. Standardize the
glass electrodes after every 10 determination.
(6) Dip the electrodes in distilled water, when not in use and ensure
that the reference electrode always contain saturated potassium
chloride solution in contact with potassium chloride crystals.

Measurement of Collecting & Filling water sample is Per No. Sample.

----------***----------
436
10.7 TESTING OF SOIL SAMPLE OBTAINED FROM AUGER (Item No.
LR 7)
Testing of soil sample obtained from auger as per depth, doing weight of
100gm of soil sample mix with distilled water in 1:2 proportion using 20
lit.For 100 samples, Testing Ec & pH of each sample filling result in prescribe
forms cleaning of equipment’s, measuring cylinder etc. complete. As
directed.

This work includes Berma pits for Water logged area & Auger Pits for Saline
area.
1 Auger Pits- During Pre-Monsoon i.e. April, may of every year. These
Auger pits will have to be taken within salt affected area as per
instructions of the Engineer-in-Charge. The depth of auger pits will be
1.2 m. or hard murum met whichever is earlier should be taken. At the
time of taking auger pits the soil samples at the depth from 0 to 20
cm.20 to 40 cm., 40 to 80 cm. & 80 to 120 cm. will be kept around the
pit in cyclic order at clockwise direction so as it is easy to sampling in
plastic bag.
2 Normal Pits-These Normal pits will have to be taken on periphery of
salt affected area as per instructions of the Engineer-in-Charge. The
depth of auger pits will be 0.4 m. or hard murum met whichever is
earlier should be taken. At the time of taking auger pits the soil
samples at the depth from 0 to 20 cm.20 to 40 cm.& will be kept
around the pit in cyclic order at clockwise direction so as it is easy to
sampling in plastic bag.
1 Record Data
Beakers, Containers & pH-meter Confirming to IS : 2711-1979,
Ec meter Confirming to IS : 14767-2000
3 Material
Distilled Water, Potassium Chloride Solution.
IS : 2711-1979 Specification for pH meter.
IS : 14767-2000 Determination of the Specific Electrical Conductivity
of Soils- Method of Test.
437
These collected samples are tested for EC and pH as per the following
procedure:
1 Testing Procedure for pH
(1) Weigh 20 gm of 2.00 mm air dry soil into a beaker. Add 50 ml of
distilled water & stir with a glass rod throughly for aboud 5
minutes & keep an hour.
(2) Dip the electrodes in the beakers containing the soil water
suspension with constant stirring.
(3) While recording pH, switch the pH meter to pH reading, wait for
30 seconds & record the pH value to the nearest 0.1 unit. Put the
pH meter in standby mode immediately after recording.
(4) Remove the electrodes from soil suspension & clean the electrodes
with distilled water.
(5) Rinse the electrodes after each determination & carefully blot them
dry with filter paper before the next determination. Standardize the
glass electrodes after every 10 determination.
(6) Dip the electrodes in distilled water, when not in use and ensure
that the reference electrode always contain saturated potassium
chloride solution in contact with potassium chloride crystals.
2 Testing Procedure for EC
(1)Calibrate the conductivity cell with the help of standard Kcl solution
& determine the cell constant.
(2) The soil water suspension of 20 gm: 50 ml ratio prepared for the
determination of pH can also be used for conductivity
measurements. After recording the pH, allow the soil water
suspension in the beaker to settle for additional half an hour.
(3) After the calibration dip the conductivity cell in the supernatant
liquid of the soil water suspension. Read the conductivity of test
solution in proper conductance range.
(4) Remove the cell from soil suspension, clean with distilled water
and dip into a beaker of distilled water. EC is expressed as ds/m.
(5) Dip the conductivity cell in distilled water when not in use.
(6) Record the temperature of soil water suspension during the test.

Measurement of Testing of Soil is Per No. Sample.

----------***----------
438
10.8 LABOUR CHARGES FOR REMOVING GRASS, THORNY SHURBS
(Item No. LR 8)

Labour charges for removing grass, thorny shurbs, Junglishurb, Kubabul and
alike grass along and in the drain/canal making the ground clean by shovel
and phavaras etc. complete. As directed.

1 As directed by Engineer-in-Charge for removing grass, thorny shrubs, jungly
shrubs, Kubabhul and alike grass along road side making the ground clean by shovel
and phavaras etc. labour are engaged for specific work portion.
2 The cleaning along drain inspection path and road are to be done with the help of
labours.

1 Record Data
Command Map, Schematic Plan of Drainage Scheme.
2Instruments / Devices
Not Applicable.
3 Material
Not Applicable.

As directed by Engineer-in-Charge.
Measurement of Labour Charges is Per Sqm.

----------***----------
439
10.9 TAKING OPEN PITS, ONE OPEN PIT PER SQ.KM. (Item No. LR 9)

Taking open pits, one open pit per sq.km., including refilling of open pit after
taking down all necessary morphological observation. Size of pit - Length 2.5
m. x Width 1.20 m and Depth of open pit up to 2.50 m. or up to hard strata if
met first etc. complete, as directed.

With the use of topo analysis, identified physiographic units are transferred on
cadastral map which is used as a base map for conducting soil survey. Open
profiles are taken at least one profile per 100 ha. The intensity of open profiles
can be increased if the area is heterogeneous and complex physiographic. The
purpose of taking open profile is to obtain detailed information of the
morphology, physical & chemical characteristics of each units occupying a
significant area of the project.

1 Record Data
Base map (Command map), Munsell soil colour chart, Open
profile book
Magnifying Glass, Camera, Measuring tape, Compass, Abney
level
3 Material
Pickaxe, Spade, Crowbar, Ghamela, Dagger, Wooden peg, Water

bottles, base map, soil sample bags, 3N HCl,etc.

Reference to Specifications
Soil Survey Guidelines, Superintending Engineer and Director,
Irrigation Research and Development, Pune-411001 (Publication year -
2014)
IS : 5510-1969 Guide for soil surveys for river valley projects

1 Contractor should excavate open pits at predetermined locations of
length 2.5 m x width 1.20 m and depth up to 2.50 m or up to hard strata
if met first. The depth of open pit will be recorded in open profile
booklet. The open pit shall not be excavated near tree, field bund or
well.
2 Morphological observations such as name of Horizon, Soil depth (cm),
Average thickness of horizon, Boundaries of horizons and layers, Soil
condition, Soil colour with the help of Munsell colour chart, Mottles,
Coarse fragments nature and abundance, Texture by feel method, Soil
440
Structure, Soil consistency in dry moist and wet condition, Concretions
– size shape and abundance, Soil reaction (Effervescence with dilute
HCL), Roots quantity size and location of roots in each layer etc. are
observed by Senior scientific Assistant/ Junior scientific Assistant and
recorded in the open profile proforma in the Open profile booklet. After
noting the observations by Senior scientific Assistant/ Junior scientific
Assistant in open profile booklet. Contractor should immediately refill
the open fit as the observations taken by the Senior scientific Assistant/
Junior scientific Assistant with the permission of field Incharge (Senior
scientific Assistant/ Junior scientific Assistant).
3 Sample Collection- Soil sample of 1 Kg. from each identified horizon
collected in soil sample bag with the help of labour provided by the
contractor.
4 Man power-Semi skilled-3 & skilled labour-1.

The measurement shall be submitted by the contractor by way of
superimposing the executed work on the designed cross-sections which
are prepared prior to the start of the work at the prescribed intervals.
Sr. Village Sy. Cross Open Depth No. of Open

No. No. section Pit in m soil profile
No. No. samples book No./
collected Page No.

Payment is done after the submission of Measurements and Bill in
duplicate after the completion of work.
The contract rates shall be per No. The rates shall be same to all open
pits.
----------***----------
441
10.10 CARRYING OUT INFILTRATION TESTS AT THE LOCATION OF
OPEN PITS (Item No. LR 10)

Carrying out infiltration tests at the location of open pits in the command area
etc. complete, as directed.
Infiltration refers to the process of downward entry of water in to the soil .
This is an important process because its rate often determines the amount of
accumulation or runoff over the soil surface during irrigation or precipitation.
1 Record Data
Base map (Command map), Open profile book
Magnifying glass, camera, Measuring tape, compass, Double-ring

Infiltrometer and stop watch
3 Material
Measuring flask, wooden plank and Hammer, plastic sheet, Mug, Bucket,
Water container,etc.
Soil Survey Guidelines, Superintending Engineer and Director, Irrigation
Research and Development, Pune-411001 (Publication year - 2014)
1 General
At the time of excavation of open pit, Infiltration test shall be taken at
the surface, 1.20 m depth and 2.50 m depth with concentric double ring
provided. The observations will be recorded by senior scientific
Assistant/Junior scientific Assistant in open profile booklet.
2 Infiltration Test-
1 Infiltration refers to the process of downward entry of water in to the

soil. This is an important process because its rate often determines the
amount of accumulation or runoff over the soil surface during irrigation
or precipitation.
2 The double-ring infiltrometer is often used for measuring infiltration rates. Ring
infiltrometer consist of a single metal cylinder that is driven partially into the
soil. The ring is filled with water, and the rate at which the water moves into
the soil is measured. This rate becomes constant when the saturated
infiltration rate for the particular soil has been reached.
442
3 There are two operational techniques used with the double-ring infiltrometer
for measuring the flow of water into the ground. In the constant head test, the
water level in the inner ring is maintained at a fixed level and the volume
water used to maintain this level is measured. In the falling head test, the time
that the water level takes to decrease in the inner ring is measured In both
constant and falling head test the water level in the outer ring is maintained at
a constant level to prevent leakage between rings and to force vertical
infiltration from the inner ring. Numerical modelling has shown that falling
head and constant head methods give very similar results for fine textured
soils, but the falling head test underestimates infiltration rates for coarse
textured soils.
3 Test Procedure for Infiltration (Cylinder infiltrometer Method)-
1 Infiltration test carried out with the help of labour provided by the
contractor with assistance of field in charge (Seniorscientific
Assistant/Junior scientific Assistant). In open pit Infiltration test shall be
taken at the surface, 1.20 m depth and 2.50 m depth with concentric double
ring provided. The observations will be recorded by Senior scientific
Assistant/Junior scientific Assistant in open profile booklet. Standard format
of proforma is as per given above.
2 In this method, two cylinders, one of 30 cm dia. And the other of 60 cm
dia. are driven concentrically into the depth of about 10 cm. The inner
cylinder is fixed with a hook gauge and scale to read the water levels. The
least count of the scale is normally one mm. The purpose of the outer
cylinder is to restrict the lateral infiltration of water from the inner cylinder.
The cylinders are of mild steel with 2 mm thick walls and bevelled edges at
the bottom. Other equipment is water container, a measuring flask, wooden
plank and hammer, plastic sheet, stop watch, etc. The detailed test procedure
is described below.
(a) Level the ground on which test is to be taken and break
clods. Clean the surface.
(b) Drive the inner cylinder in the ground to a depth of 10 cm
by placing the wooden plank on the cylinder and hammering
gently on the plank.
(c) Drive the outer cylinder concentrically to a depth of 10 cm
similarly.
(d) Fix the hook gauge to the inner cylinder.
(e) Place a plastic sheet in both the cylinder.
(f) Pour water in the inner and outer cylinder to a depth of
about 12 cm.
(g) Note the initial reading on the hook gauge when it just
touches the water level.
(h) Lower the gauge to a depth of 1 to 2 cm depending upon the
soil type.
(i) Remove the plastic sheet instantaneously and start the stop
watch. Care must be taken to see that water does not spill
out.
(j) Note the time when the level reaches the hook gauge and
again lower the hook gauge by 1 to 2 cm.
(k) Repeat step (j), till the depth in the cylinders is about 7 cm.
443
(l) Immediately after taking the reading, add measured quantity
of water in the inner cylinder so that the level is again at the
starting point. Adjust the gauge to this level and continue
the measurements of time.
(m) Repeat till the rate is almost constant.
3 This test is carried out by Senior scientific Assistant/Junior scientific
Assistant with the help of Semi-skilled labour and observations are
recorded in the open profile proforma in the Open profile booklet.
4 Alternatively, only water levels at an interval of 20 seconds in the first 3
minutes are noted. Thereafter the water levels can be noted for every
minute for the next 10 minutes and thereafter for every 5 to 30 minutes
depending upon the drop of level. When the level drops below 6 cm, water
is added to bring it to its initial level. The first procedure is a fixed
infiltration interval and the second is a fixed time interval and both give
similar results. The latter is easier during the initial stage when the
infiltration rate is high. The readings are noted in the format.
4 Man power-Semi skilled labour-1.
5 Ratings:-
Slow: - Very Slow Less than 0.05 inches per hour.
Slow 0.05 to 0.20 inches per hour.
Moderate: - Moderately Slow 0.20 to 0.80 inches per hour.
Moderate 0.80 to 2.5 inches per hour.
Moderately Rapid 2.5 to 5 inches per hour.
Rapid Rapid 5 to 10 inches per hour
Very Rapid over 10 inches per hour
superimposing the executed work on the designed cross-sections which are
prepared prior to the start of the work at the prescribed intervals.
Sr. Village Sy. No. Cross Open Depth No. of Open

No. section No. Pit in m Infiltration profile
No. tests book
carried out No./
Page No.
Payment is done after the submission of Measurements and Bill in duplicate

after the completion of work.
The contract rates shall be per Test. The rates shall be same to all tests.
----------***----------
444
10.11 CARRYING OUT PHASE LEVEL MAPPING FOR CONFIRMATION
OF MORPHOLOGICAL PROPERTIES (Item No. LR 11)

Carrying out phase level mapping for confirmation of morphological
properties of soil and their interconnection in field for various phases such as
texture, erosion, slope, salinity, rockiness, stoniness etc. complete as directed.

To observe the sub-division of a soil type having variations in characteristics
not significant to the classification of the soil in its natural landscspe, but
significant to use and management of the soil. Examples of variations
recognized by phases of soil types include difference in slope, stoniness and
erosion.
A traverse is made through' the command to note the surface texture of soils,
depths, slopes, erosion, etc. and are marked on the map.
Natural drainage conditions are studies by surveying major transverse nalas,

indicating the locations of rock out crops in the beds and sides.

1 Record Data
Base map (Command map), Open profile book
Magnifying glass, camera, compass, Abney level
3 Material
Measuring tape, etc.
Soil Survey Guidelines, Superintending Engineer and Director,
Irrigation Research and Development, Pune-411001 (Publication year -
2014)

For carrying out Phase level mapping shall be provide one skilled labour to
carry out material and equipment’s for mapping. All the observations and
phase level mapping for confirmation of morphological properties of soil and
their inter connections in field for various phases such as 12 soil textural
classes of soil, erosion classes, soil slope - refers specially to the slope of land
immediately surrounding the profile i.e. within 100 m, Soil salinity,
rockiness- the distance between the rock outcrops and their percentage
coverage in the field is to be recorded, stoniness - The approximate amount of
445
stones and boulders present at the surface has to be assessed separately and
reported etc. should taken by Senior scientific Assistant/Junior scientific
Assistant in open profile booklet with the help of one skilled labour.
Man power- Skilled labour-1
superimposing the executed work on the designed cross-sections which are
prepared prior to the start of the work at the prescribed intervals.
Sr. Village Cross Auger pit No. Of Open profile book

No. section No. number Auger pits No./ Page No.
Number of sq. Km. = Total number of Auger pits

6.25
Payment is done after the submission of Measurements and Bill in duplicate
after the completion of work.
The contract rates shall be per Sq. km.
----------***----------
446
10.12 CARRYING OUT DRYING, POUNDING, SIEVING OF SOIL
SAMPLES (Item No. LR 12)

Carrying out drying, pounding, sieving of soil samples in laboratory including
washing the sets of soil samples after every test and discarding of tested soil
samples at laboratory etc. complete as directed.

Preparation of soil sample for physical and chemical tests in soil sample
testing laboratory.
1 Record Data
Soil Sample list, Laboratory Register
Oven
3 Material
2 mm and 0.5 mm stainlesssteel sieve, Enamel dish, wooden mortar
and pestle, 2 mm or 0.5 mm stainlesssteel sieve, Soil sample bag,
Permanent marker pen etc.
Laboratory Testing Procedure for Soil and Water sample Analysys,
Superintending Engineer and Director, Irrigation Research and
Development, Pune-411001 (Publication year - 2009)

1 Soil Sample Preparation for analysis:
2 The collected soil samples are homogeneously mixed and left to attain
equilibrium with air for 2 hours in the trays/paper dishes.
3 If the samples are dry there is no need to keep the samples in the oven
in the soil sample testing laboratory. It can be directly taken for further
testing.
4 If the soil samples are wet, samples are dried in the oven at 250 C for 2
hours or more (depending upon the wetness of the sample). If samples
found sticky even after drying, then the temperature may be raised by 2
to 50 C, but in any case it should not exceed 350 C.
5 After drying the soil, clods are crushed gently and grounded with help
of wooden pestle and Mortar, Gravel, Soft chalk, Limestone, Stones
and Concretions should be removed from the samples.
6 The soils are passed through 2.0 mm and 0.5 mm stainless steel sieve.
The sufficient quantity of sieved soil sample is kept in plastic bag
labeled with permanent ink marker (Lab no.) in assistance with lab in
charge (Research Assistant/ Lab Assistant).
447
7 The plant residues, gravel and other materials retained on the sieve
may be discarded.
8 If the gravel content happens to be substantial, the percent of the
sample shall be recorded by Research Assistant/ Lab Assistant.
9 After testing of soil sample by Research Assistant/Lab Assistant
discarding will be done by the permission of Office in charge in open
area to fill up shallow area nearby or, soil samples will be used by any
government office for gardening purpose in office premises.

The measurements are recorded per soil sample.

The rates shall be same to all soil samples. Payment is done after
completion of work.
----------***----------
448
For Office Use Only
SECTION 11
SPECIFICATION FOR
MAINTENANCE & REPAIRS ITEMS
2022-23
449
SPECIFICATION FOR MAINTENANCE & REPAIRS ITEMS
11.1 DESCRIPTION OF ITEM

Dismantling the Stone Masonry in cement mortar including stacking the material with
all lifts etc.complete as directed.. (Item No. MR 1).
11.1.1 GENERAL
The item provides for the complete removal of the existing structure except
such portions asmay be required or permitted to be left in place as shown on the
drawing or as directed by the Engineer, clearing the site, sorting out useful material
and stacking them nearly within a lead of 100 m or on the bank indicated by the
Engineer whichever is more.
11.1.2 PRELIMINARIES
If necessary and directed by the Engineer the contractor shall have to erect
screens of canvas or other suitable materials and/or water the structure and area to
avoid the nuisance of dust before and during dismantling. Care shall be taken to
be that dismantling is done in such sequence and manner as to prevent all
avoidable damage to usable materials and any damage to nearby property or injury
to life.
In case of structures which are to be removed for re-errection, all members shall
be properly match marked with paint. The pins, nuts, plates, structural steel
members timber etc shall be similarly marked for identification of their position
in the entire assembly. All machined surfaces pin holes, pins, etc shall be coated
with grease. An inventory of all possible serviceable materials shall be kept on
record and signature of the contractor obtained in token of his acceptance. Any
doubt or non agreement with the same shall be reported by the contractor before
starting the removal.
Portions required to be kept intact shall be clearly marked before starting
dismantling.
If no separate provision exists in the tender for necessary diversion, the contractor
shall over the less invariably be responsible for the construction and maintenance
of adequate barriers, watchmen and/or lights at the ends of portions of the road
closed by construction to the satisfaction of the Engineer at his (contractor's) cost.
A register shall be opened by the contractor on the work site to show a day-to-day
account of the turnout, salvaged materials and whether properly stacked or wasted.
It shall be signed by the representative of the contractor and a responsible member
of the Dept. supervising staff every day.
11.1.3 DISMANTLING AND REMOVAL

The structure shall be dismantled carefully and the materials removed
without causing damage to the serviceable materials to be salvaged, the part of the
structure to be retained and any properties or structures nearby. Any avoidable
damage to articles to be salvaged and part of the structure to be retained and any
damage to nearby property or structure shall be made good by the contractor
without extra claims. The contractor shall be responsible for any injury to the
450
workers or the public.
Unless otherwise specified the structure shall be removed up to 45 cm
below the ground level and the portion which interferes in any way with the new
construction shall be removed entirely. Removal of overlying or adjacent materials
if required for the dismantling of the structure, shall be included in the item.
Where existing bridge is to be extended or otherwise incorporated in the
new work, only such part or parts of the existing structure shall be removed as are
necessary to provide a proper connection to the new work. The connecting edges
shall be cut, chipped and trimmed to the required lines and grades without
weakening or damaging the part of the structure to be retained.
Blasting if required, may be resorted to with the written permission of the
Engineer. In such case blasting shall be carried out as specified .All blasting
operations shall be finished before the new construction is commenced.
Equipment or methods which might damage members, portions of the
structure to be preserved or adjacent construction or structure shall not be used.
11.1.4 DISPOSAL
All the materials obtained from the removal of the structure shall be the
property of Government. Useful materials shall be stacked neatly in such a manner
as to avoid deterioration and in places directed by the Engineer within a lead of
100 m or on the bank indicated by the Engineer whichever more is. Different
categories of materials shall be stacked separately.
Unless otherwise provided, excavated materials shall be used in backfilling
excavation made in removing the structure, in constructing embankment or
otherwise disposed off as directed within 100 m free of cost.
Useful materials will be issued to the contractor for use in the new work or
elsewhere at the rates provided in the tender or when not so provided at the rates
agreed upon by the Engineer and the contractor.
Non useful materials shall be wasted by the contractor without causing any
damage or in convenience.
11.1.5 FINAL CLEARANCE

All rubbish shall be cleared off the site and the ground left clean and clear.
Any damage caused during the operation shall be made good.
11.1.6 RESPONSIBILITIES
The contractor shall be responsible for
i) Maintaining a register of the salvaged materials
ii) Keeping intact the portion not to be removed
iii) Avoidable damage to serviceable articles to be salvaged during dismantling
conveyance and stacking
iv) Blasting operations when necessary
v) Stacking neatly and safe custody of the salvaged materials till handing over to
the department
vi) Disposing off unserviceable materials and its consequences
vii) Damage to nearby property and injury to workers and the public due to his
operation.
451
11.1.7 ITEM TO INCLUDE
1) All labour, materials, use of equipment, tools and plants required for
completing the job satisfactorily.
2) Erecting and removing screens and watering when necessary and directed
3) Marking the structure suitably
4) Opening register of salvaged materials
5) Providing adequate barricades, sign, lights, etc
6) Removal of the structures
7) Diverting the existing drains, road, etc temporarily and redoing the same, if
not separately provided
8) Stacking serviceable materials.
9) Wasting unserviceable materials
10) Clearing site on completion
11) Compensation for damaged properties or injuries to persons
11.1.8 MODE OF MEASUREMENT AND PAYMENT

The work shall be measurement and paid at specific rate mentioned in schedule-
B on cubic meter basis.
452
11.2 DESCRIPTION OF ITEM
Dismantling the old lime concrete or cement concrete including stacking the material
with all lifts etc.complete as directed..( Item No. MR 2)
11.2.1 DESCRIPTION: -
This Item shall govern for breaking up and satisfactorily disposing of
concrete canal structures.
11.2.2 SCOPE OF WORK: -

Existing canal structure concrete to be disposed of, shall be removed and
legally disposed of offsite. The use of explosives for breaking up old concrete will
not be permitted, unless authorized by the Engineer, and when so authorized,
adequate precautions shall be given to prevent damage to adjacent property.
Reinforcing steel shall be cut as necessary for satisfactory disposal. Where
only a portion of the existing concrete is to be removed, special care shall be
exercised to avoid damage to that portion of the concrete to remain in place. The
existing concrete shall be cut to the neat lines shown on the plans or established
by the Engineer and any existing concrete, beyond the neat lines so established,
which is damaged or destroyed by these operations shall be replaced at the
Contractor's entire expense.
Full depth or as shown on the drawings, will be required and shall be
incidental to the removal of old concrete. Where indicated on the plans, old
concrete which is removed shall be loaded, hauled and disposed of at permitted
locations outside the project limits, or used as needed for riprap onsite. Broken
concrete reused as riprap onsite will be incidental to this Item. The Contractor
shall provide the disposal locations and the total quantity of all excavated material,
and the total quantity of disposed material.
The disposal site shall not be an environmentally sensitive area, “Water of
the United States”, wetland, or floodway. It is the responsibility of the Contractor
to contact the proper authorities to determine land use classification and to obtain
any necessary permits.
If the disposal site is defined in the plans, then the County shall be responsible
for ensuring that the appropriate Department of the Army permit has been obtained
for the activity, as necessary. Work performed under this Item shall be initiated at
such time and prosecuted in such a manner as to cause a minimum of
inconvenience to traffic or adjacent property owners.
11.2.3 MODE OF MEASUREMENT: -

Existing concrete removed as prescribed above, will be measured by the
cubic meter in its original position.
11.2.4 MODE OF PAYMENT: -

The work performed as prescribed by this Item, measured as provided under
"Measurement" will be paid for at the unit price bid for "Removing Old Concrete"
(of the type specified), which price shall be full compensation for Full depth cutting
and breaking up the concrete, cutting reinforcing steel when required, loading,
hauling and disposing of the material offsite and for all labor, tools, equipment,
manipulations and incidentals necessary to complete the work.
453
11.3 DESCRIPTION OF ITEM:-
Dismantling R.C.C. works and removing the stuff to a distance of 15 m and all lifts
including stacking etc. complete as directed.(Item No. MR 3)
11.3.1 DESCRIPTION: -
This Item shall govern for breaking up and satisfactorily disposing of
concrete canal structures.
Existing concrete to be disposed of, shall be removed and legally disposed of
offsite. The use of explosives for breaking up old concrete will not be permitted,
unless authorized by the Engineer, and when so authorized, adequate precautions
shall be given to prevent damage to adjacent property.
Reinforcing steel shall be cut as necessary for satisfactory disposal. Where
only a portion of the existing concrete is to be removed, special care shall be
exercised to avoid damage to that portion of the concrete to remain in place. The
existing concrete shall be cut to the neat lines shown on the plans or established by
the Engineer and any existing concrete, beyond the neat lines so established, which
is damaged or destroyed by these operations shall be replaced at the Contractor's
entire expense.
Full depth or as shown on the drawings, will be required and shall be
incidental to the removal of old concrete. Where indicated on the plans, old
concrete which is removed shall be loaded, hauled and disposed of at permitted
locations outside the project limits, or used as needed for riprap onsite. Broken
concrete reused as riprap onsite will be incidental to this Item.
The Contractor shall provide the disposal locations and the total quantity of
all excavated material, and the total quantity of disposed material. The disposal site
shall not be an environmentally sensitive area, “Water of the United States”,
wetland, or floodway.
It is the responsibility of the Contractor to contact the proper authorities to
determine land use classification and to obtain any necessary permits. If the
disposal site is defined in the plans, then the County shall be responsible for
ensuring that the appropriate Department of the Army permit has been obtained for
the activity, as necessary.
Work performed under this Item shall be initiated at such time and
prosecuted in such a manner as to cause a minimum of inconvenience to traffic or
adjacent property owners.
11.3.3 MODE OF MEASUREMENT: -
Existing concrete will be measured by the cubic meter in its original position.
11.3.4 MODE OF PAYMENT: -

The work performed as prescribed by this Item, measured as provided under
"Measurement" will be paid for at the unit price bid for "Removing Old Concrete" (of the
type specified), which price shall be full compensation for Full depth cutting and breaking
up the concrete, cutting reinforcing steel when required, loading, hauling and disposing of
the material offsite and for all labor, tools, equipment, manipulations and incidentals
necessary to complete the work.
454
Cleaning grass and removal of rubbish up to a distance of 50 metres outside the
periphery of the area. (Item No. MR 4)
11.4.1 DESCRIPTION:-
This Item shall govern for conducting clearing and grubbing operations
within the project limits from right-of-way line to right-of-way line. For the purpose
of this Item, the project limits shall include canal and other areas as shown on the
drawings.
Clearing shall consist of removing all trees, brush, overhangs, logs, tires,
appliances, trash, rubbish and other debris, including any deleterious materials, that
exist within the limits of the project.
Grubbing shall comply with the requirements of the third paragraph of
Section 102.2 below. It shall be the responsibility of the Contractor to visit the
project site and ascertain the clearing and grubbing requirements as included in the
bid documents prior to submitting a bid on the project. Any necessary trimming of
overhangs that encroach into the right-of-way and interfere with the facilitation of
construction or the operation or maintenance of the executed project shall be
required and will not be paid for separately.
11.4.2 SCOPE OF WORK:-
The project limits shall be cleared of all trees, brush, stumps, overhangs, logs,
rubbish, shrubs, and other trash. Items and certain areas designated by the Engineer
for preservation shall be carefully protected from abuse, marring or damage during
construction operations and preserved in accordance with the bid documents.
Parking and/or servicing of equipment, or stockpiling of construction materials
within 3 feet of the drip line of trees designated for preservation, will not be
permitted.
On areas required for canal or structural excavation, grubbing shall be
conducted to remove all stumps, roots, etc., to a depth of approximately 2 feet
below the lower elevation of the excavation. On areas required for embankment
construction, grubbing shall be conducted to remove all stumps, roots, etc., to a
depth of approximately 2 feet below the existing ground surface.
All holes remaining after clearing and grubbing shall be backfilled with
suitable onsite material and compacted to 95 percent of Standard Proctor Density
(ASTM D698 “Standard Test Methods for Laboratory Compaction Characteristics
of Soil Using Standard Effort (12,400 ft-lbf/ft3 )”) at a moisture content of between
optimum and +/- 3 percent of optimum as directed by the Engineer and the entire
area bladed to prevent ponding of water and to provide drainage; except in areas to
be immediately excavated, the Engineer may direct that the holes not be backfilled
on areas required for borrow sites and material sources, stumps, roots, etc., shall be
removed to the complete extent necessary to prevent such objectionable matter
becoming mixed with the material to be used in construction.
455
11.4.3 DISPOSAL OF MATERIALS:-
All cleared and grubbed materials shall be disposed of offsite. The Contractor
shall be responsible for obtaining any necessary disposal permits. The Contractor
shall not bury any refuse on Harris County property. The disposal site shall not be
an environmentally sensitive area, “Waters of the United States”, wetland, or
floodway. It is the responsibility of the contractor to contact the proper authorities
to determine land use classification and to obtain any necessary permits. If the
disposal site is defined in the plans, then the County shall be responsible for
ensuring that the appropriate Department of the Army permit has been obtained for
the activity, as necessary. No burning shall be allowed unless otherwise noted. The
Contractor shall refer to Item 560 “Maintenance and Cleanup of the Project Site”
for schedule and frequency of cleanup of materials for disposal.
11.4.3.1 Limit of Operation:-
No clearing or grubbing shall be done outside the Project limits or the right-
of-way. Any work done outside the Project limits or the right-of-way limits, for any
purpose, shall be done at the Contractor's expense and it shall be the Contractor's
responsibility to negotiate and secure the permission of the property owner for such
operation. The Contractor shall provide sufficient evidence to Harris County that
such permission has been obtained.
11.4.3.2 Schedule of Clearing:-
The Contractor shall schedule his clearing operations so that clearing has been
completed for a distance of 2,000 feet ahead of any point where excavation is to be
started. After starting excavation, the Contractor shall keep a minimum of 1,000
feet of cleared right-of-way ahead of the excavation operation.
11.4.4 MODE OF MEASUREMENT &PAYMENT:-
Clearing and grubbing will be paid for at the unit price bid per square meter,
as designated in the proposal and/or drawings, and shall be full compensation for
furnishing all labour, materials, permits, supervision, equipment and supplies
required to complete all items of work specified herein. Removal of concrete
structures shall be measured and paid for in accordance with Item 104 “Removing
Old Concrete” and Item 495 “Removing Old Structures”.
456
Cutting down trees including cutting trunks & branches and stacking the material
with all lift including uprooting and refilling the pit with material etc. complete as
directed. (excluding extra material required for refilling)(Item No. MR 5).
a) above 30 cm to 60 cm girth
b) above 60 cm to 90 cm girth
c) above 90 cm to 1.5 m. girth
d) above 1.5 m. to 3.0 m. girth
e) above 3.0 m. to 4.5 m. girth
11.5.1 GENERAL:-
The item includes cutting of trees having girths specified as above, measured
one meter above the ground and standing within and without the canal, road land
as directed by the Engineer, the trees to be cut shall be duly marked to distinguish
them from the trees not to be cut. The trees 30 cm. (about 1’) in girth and below
shall be removed under clearing site of the particular item and shall not be paid for
separately.

The trees marked for cutting shall be cut without disturbing or
inconveniencing traffic. Where the cut trees are likely to cause damage to any
property, are to be left standing, road, canal site, Dam Site etc., ropes and guys
shall be used to cause the tree to fall in a guided direction in a harmless manner.
Where necessary to prevent injury to structure, road, property or other trees or to
avoid damage and obstruction to traffic, trees shall be cut in a section from top
downwards. Ones cut across the trunk just near the ground level to a uniform depth
shall first be taken and the tree shall then be pulled by means of ropes so the roots
and as to separate it from the roots and fall in the guided direction. If the tree cut
falls in a manner to interrupt or obstruct the traffic, necessary diversions shall be
prepared and maintained according to:-
11.5.2.1 Diversion:-
when the traffic can be allowed on the roadside berms without much
inconvenience to traffic or impediment to the work, this shall be provided by the
contractor at his own cost. He shall provide the necessary barricading, warning
boards and signals and watchmen by day and lights at night. Otherwise, a separate
diversion shall be provided according BR.1.
So as to be safe for the traffic over it till the obstruction to the tree is entirely
removed and the road surface restored to normal condition. Warning signals shall
be displayed on either side of the obstruction. If the tree cannot be removed by
sunset, warning red lights to indicate the danger shall be displayed from sunset to
sunrise at sunset at warning 50 m. on either side or the obstruction till it is
completely removed. Cost of preparing, maintaining, and operating diversions,
providing warning boards, signals, etc., shall be borne by the contractor. The
contractor shall take every precaution to safeguard the nearby property, crop and
457
travelling public. If any damage to property or injury to life occurs due to the
contractor's default in this respect, he shall be liable to compensate such damage
or injury.
11.5.2.2 Grubbing:-.
In canal, road cutting, all stumps and roots shall be removed to a depth of not
less than 30 cm. below the graded formation and slopes. Under embankments they
shall be removed to a depth of 15 cm. below original ground level or 30 cm. below
formation level whichever is more. Outside embankments and cuttings, they shall
be removed up to 15 cm. below ground level. All the excavations made for grubbing
shall be filled with excavated material in 15 cm. layers rammed.
11.5.3 DISPOSAL OF MATERIALS:-

All the products of cutting trees shall be the property of Government. All
timber from which sawn logs and posts can be produced shall be cut into
merchantable lengths as directed by the Engineer. Such timber will not be required
to be cut to less than 3 m. lengths. Other types of trunks and bigger branches shall
be cut into pieces of 1 m. or so and kept in neat stacks as directed within a lead of
50 meters . Smaller branches and thinner pieces shall be stacked separately and
very thin leafy portion destroyed or removed as directed. The contractor shall be
responsible for the custody of the cut materials till handed over to the Department.
11.5.3.1 Item to include.-
1. Cutting the trees, grubbing roots and stacking the materials neatly and their safe
custody.
2. Displaying of warning signals and red lights.
3. Diversions.
4. Making good any damage to the canal, road surface and compensation for any injury
to life and property due to default of contractor.
5. All labor, materials and use of equipment required to execute the work satisfactorily.
11.5.4 MODE OF MEASUREMENT AND PAYMENT:-

Measurement shall be for the number of trees cut of different sizes having
girths of more than 30 cm. The girth shall be measured at a height of one meter from
the ground before cutting and grouped under following size categories.
a. Above 30cm to 60cm girth
b. Above 60cm to 90cm girth
c. Above 90cm to 1.5m girth
d. Above 1.5m to 3.0m girth
e. Above 3.0m to 4.5m girth
458
Numbering road and canal sites trees including painting etc. Complete as
directed.(Item No. MR 6)
11.6.1 SCOPE OF WORK :

Providing painting, figuring and numbering as per IRC specifications complete
with Synthetic Enamel Paint for ordinary Km. Stone.
(i) Two coats on new work.
(ii) One coat on old work.
Providing painting, figuring and numbering as per IRC specifications complete
with Synthetic Enamel Paint for 0.2 Km. Stones or Boundary Stones.
(i) Two coats on new work.
(ii) One coat on old work.

Measurement and payments shall be done on number basis.
459
Removing dry silt from the canal bed and stacking as directed with all lift etc.
Complete as directed.(Item No. MR 7)

• If excavated pits get sited due to intervening floods, slips or any other cause, till
completion of the work, the Contractor shall excavate and restore the pits and
section to the required shape and dimensions without any extra cost.
• Excavation and removal of silt or silt mixed with sand in slushy condition from
canal bed including disposing off the same in spoil bank or on the canal
embankment in layers as directed etc., complete with initial lead upto 50 m and all
lifts.
• This shall include all kinds of rock or shale, indurate clay, soil, sit sand and gravel,
soft average and hard murum and any other materials which can best be removed
with a shovel after loosening with a pickaxe and /core bar. It shall also include
isolated boulders up to 0.1 cubic metre each, which does not need blasting and
could be removed with a pickaxe/core bar and shovel. All the excavated materials
from the soft strata shall be sorted out . The material not useful for bank work shall
be deposited as directed by the Engineer-in-charge. Material useful in bank work
shall be sorted out to be used in hearting or casing. Each stock pile of un required
material shall be of regular size and not less than 5 m. in height.
• Unless otherwise specified, no distinction will be made as to whether the material
being excavated is dry, moist or in wet condition. Dealing with the ground water or
rain water collected and its disposal is covered under relevant items of excavations
and will not be paid for separately.
11.7.2 MODE OF MEASUREMENTS& PAYMENT:

The measurements shall be based on areas of cross sections taken normal to
the axis of the structure or its part of the original ground surface and the surface of
the finally completed excavation within the pralines, taken at every 10 meters along
the axis of structure or its part. Where there is abrupt change in depth, additional
cross sections may be taken at the discretion of the Engineer-in-charge. levels along
the cross section shall be taken at every 15 to 20 meters as per exigency of work.
The measurement shall be recorded on cubic meter basis of silt removal cross
section and Payment will be made on cu.mt. at the specified rate agreed in the
Schedule B of the tender.
• During the excavation of the work running payment for the items of excavation will
be made to Contractor 90 percent of his tendered rate for the items. The remaining
payments for these items will be progressively released depending upon the
progress of completion of the item of excavation .This part rate will be reviewed by
the Engineer-in-charge. when he feels necessary and decision of the Engineer-in-
charge. Shall be final and binding on the Contractor.
be made to the Contractor on the basis of cross-sectional measurements.
• Quantities shall be computed from the cross-sectional area by the trapezoidal
formula.
460
Removing wet silt from canal bed with 15.00 mtr. lead and all lift including depositing
the excavated stuff etc. Complete as directed. (Item No. MR 8).
• If excavated pits get silted due to intervening floods, slips or any other cause, till
completion of the work, the Contractor shall excavate and restore the pits and
section to the required shape and dimensions without any extra cost.
• Excavation and removal of silt or silt mixed with sand in slushy condition from
canal bed including disposing off the same in spoil bank or on the canal
embankment in layers as directed etc., complete with initial lead up to 50 m and all
lifts.
• This shall include all kinds of rock or shale, indurate clay, soil, sit sand and gravel,
soft average and hard murum and any other materials which can best be removed
with a shovel after loosening with a pickaxe and /core bar. It shall also include
isolated boulders up to 0.1 cubic metre each, which does not need blasting and
could be removed with a pickaxe/core bar and shovel.
• All the excavated materials from the soft strata shall be sorted out . The material
not useful for bank work shall be deposited as directed by the Engineer-in-charge.
Material useful in bank work shall be sorted out to be used in hearting or casing.
Each stock pile of un required material shall be of regular size and not less than 5
m. in height.
• Unless otherwise specified, no distinction will be made as to whether the material
being excavated is dry, moist or in wet condition. Dealing with the ground water or
rain water collected and its disposal is covered under relevant items of excavations
and will not be paid for separately.
11.8.2 MODE OF MEASUREMENTS& PAYMENT:

The measurements shall be based on areas of cross sections taken normal to
the axis of the structure or its part of the original ground surface and the surface of
the finally completed excavation within the pralines, taken at every 10 meters along
the axis of structure or its part. Where there is abrupt change in depth, additional
cross sections may be taken at the discretion of the Engineer-in-charge. levels along
the cross section shall be taken at every 15 to 20 meters as per exigency of work.
The measurement shall be recorded on cubic meter basis of silt removal cross
section and Payment will be made on cu.mt. at the specified rate agreed in the
Schedule B of the tender.
be made to Contractor 90 percent of his tendered rate for the items. The remaining
payments for these items will be progressively released depending upon the
progress of completion of the item of excavation. This part rate will be reviewed by
the Engineer-in-charge. when he feels necessary and decision of the Engineer-in-
charge. Shall be final and binding on the Contractor. During the excavation of the
work running payment for the items of excavation will be made to the Contractor
on the basis of cross-sectional measurements. Quantities shall be computed from
the cross-sectional area by the trapezoidal formula.
461
Removing old paint from steel and other surface with flame, cleaning and making
the surface even including scaffolding etc. Complete as directed.
(Item No. MR 9).
11.9.1 SCOPE OF WORK –

• Hot air paint stripper Method - Hot air is produced by an electric filament and the
heat can usually be adjusted. The tool is designed to soften and blister oil-based
paints and varnishes – the paint is then scraped away. This system is mostly used
for removal of paint from timber. It is not suitable for the removal of water-based
paints or for removing paint from plaster or slate (which may exfoliate if exposed
to such concentrated heat).
• Burning off method - This is similar to the hot air method but higher temperatures
are reached. The flame of a blowlamp is used to burn off the paint.
11.9.2 CLEANING:-
• Cleaning operations shall precede painting so that paint may be applied to clean
surfaces. The work shall be carried out in such a manner that the dirt and matter
removed by cleaning will not come in contact with freshly applied paint.
• The method to be applied for cleaning and preparing surfaces for painting shall be
mentioned in the specifications for each type of surface. When not so mentioned,
any suitable method approved by the Engineer for exposing the original surface
without damage shall be adopted

The contract rate shall be per unit of one square meter of painted surface. The linear
dimension shall be measured correctly up to 2 places of decimal of meter. The area
shall be worked out correct up to 2 places of decimal of the square meter.
462
Providing and applying Primer Red Oxide Paint in two coats including surface
preparation, chipping the welding, cleaning spatters, dust etc. Complete as directed.
(Item No. MR 10).

11.10.1.1 Material –
Oil modified alkali base primer suitably pigmented with micro fine red oxide and
extender free from heavy metals like lead, Mercury and chromium.
11.10.1.2 Direction for use-
• Ensure that the surface is free from dust, dirt, loose particles and moisture.
• One or two coats of primer can be used depending on its requirement. for the best
result it is advisable to give 10 8 to 10 hours drying time before application of
subsequent coats.
• Do not over thin & stir well before use.
11.10.1.3 Surface preparation and painting procedure –
• Remove grease oil and other content contaminants preferably by using bison
degreasing solvent. Blast clean to a minimum of standard 2 ½ with a surface profile
not exceeding 35 to 40 microns.
• If blasting is not practical make full use of mechanical tools along with manual
chipping and Wire rushing to remove loose rust. Excessive brushing of steel is to
be avoided.
11.10.1.4Protection:-
Painted surface shall be protected from sun, rain, condensation,
contamination or surface damage until it is dry due to the fullest extent. Board
indicating “wet paint” shall be put up where necessary.
11.10.2 GENERAL:-
1. Knotting shall be done by any one of the methods as approved by the Engineer.
2. The number of finishing coats shall be as mentioned in the item in addition to
priming coat.
3. The paint for finishing coat shall be of the shade and color as approved by the
Engineer.
4. Each coat shall cover the area to be painted completely and shall comprise of
crossing across the grain and laying off along the grain.
5. The number of finishing coat shall be mentioned in item.
11.10.2.1 Items to include:- The rate of the items includes all labour, material and use of
tools necessary to carry out the following operations:-
1. Supplying the approved paint for priming and finishing Coat
2. Preparing the surfaces including knotting for receiving the primer and finishing
coats.
3. Scaffolding including its erection and dismantling.
4. Application of primer coat as specified.
5. Application of finishing coat of paint.
463
6. Protecting the painted surface till dry.

The contract rate shall be per unit of one square meter of painted surface.
The linear dimension shall be measured correctly up to 2 places of decimal of
meter. The area shall be worked out correct up to 2 places of decimal of the square
meter.
464
Providing and applying anticorrosive coal tar black paint IS 290-1961 in two coats
including surface preparation, chipping the welding, cleaning spatters, dust etc.
Complete as directed. (Item No. MR 11)
(IS 290:1961, IS 2074:1992 etc)

11.11.1.1 Material –Coal tar blended with polyamide curing agent along with suitable
amount of pigments solvent and thixotropic additives.
11.11.1.2 Protection:- Painted surface shall be protected from sun, rain, condensation,
11.11.2 GENERAL:-
priming coat.
Engineer.
11.11.2.1 Items to include:-
The rate of the items includes all labour, material and use of tools necessary to
carry out the following operations:-
coats.

The contract rate shall be per unit of one square meter of painted surface. The
linear dimension shall be measured correctly up to 2 places of decimal of meter.
The area shall be worked out correct up to 2 places of decimal of the square meter.
465
Providing and applying anticorrosive Coal Tar Epoxy paint for upstream side in two
coats including surface preparation, chipping the welding, cleaning spatters, dust etc.
Complete as directed.(Item No. MR 12)

11.12.1.1 Material:
• The medium of the coal tar epoxy paint shall consist essentially of a suitable coal
tar together with an epoxy resin and curing agent. The paint shall be a two-pack
material.
• One component (base) shall consist of a suitable epoxy resin along with solvents,
pigments/extender and thixotropic agent. The amount of epoxy resin as
determined shall not be less than 35 percent of the non-volatile vehicle of the paint.
Its epoxide equivalent when estimated by shall be between 450-500.
• The second component (hardener) shall consist of a suitable coal tar blended with
polyamide curing agent along with suitable amount of solvents, pigments and
thixotropic additives. The amount of curing agent shall be sufficient to fully cure
the Epoxy resin to conform to the requirements of the specification.
11.12.1.2 Cleaning:- Cleaning operations shall precede painting so that paint may be applied
to clean surfaces. The work shall be carried out in such a manner that the dirt and
matter removed by cleaning will not come in contact with freshly applied paint.
The method to be applied for cleaning and preparing surfaces for painting shall be
without damage shall be adopted.
11.12.1.3 Application:-
• The primer coat of the paints shall be applied as soon as possible after the surface
has been cleaned before the deterioration of the surface by rust (in case of Steels
faces) and contamination of the surface by dust, dirt or any other foreign material
for all surfaces. Preferably painting should be done immediately after cleaning on
the same day. If rusting occurs after the surface is prepared for the there is
contamination of cleaned surface with salt, acid, alkali or other harmful materials
before the priming coat is applied and between the application of the remaining
coats of paint, the surfaces shall be cleaned again.
• Paints shall not be applied when the air is misty or atmospheric conditions are such
as to promote condensation or in the opinion of the Engineer, the conditions are
otherwise unsatisfactory for the work. Painting shall normally be done only in dry
weather. It shall not be applied upon damp and moist surfaces.
• Paint may be applied by spraying or brushing. Unless and otherwise specified paint
shall be applied with brush. Paint shall be worked into all crevices and corners where
possible and surface not accessible to accessible to brushes shall be painted by
sheepskin or spray or any other method approved by the Engineer. All runs or sags
shall be brushed out. Painting shall be done in a neat and workmanlike manner.
Paint shall be applied so as to produce a uniform even coating over the entire
surface, free from steaks, pitting, wrinkles or other irregularities.
466
• The number of priming and finishing coat shall be as specified for the particular
item. Sufficient time shall be allowed for one coat of paint to dry before the next is
applied.
11.12.2 GENERAL:-
priming coat.
Engineer.
11.12.2.1 Items to include:- The rate of the items includes all labour, material and use of
coats.

467
Providing and applying two coats of flat oil paint of approved colour and shade to
internal / external plastered surfaces including scaffolding if necessary, clearing and
preparing surfaces excluding primer paint etc. Complete as directed.(Item No. MR
13).
(IS - 1477 (Part-1) 1959)

11.13.1.1 Oil Paints:-
• The specifications cover the requirement for oil paint to be used as a finishing
material with respect to its composition, form, condition and tests to be carried out.
Unless expressly permitted in the special provisions or directed by the Engineer,
nothing but readily mixed (factory mixed) paint satisfying the I.S. specifications
for the particular paints shall be used.
• All paint, thinners etc. should be preferably be kept in a separate store that is well
ventilated and free from excessive heat, sparks flame or direct rays of the sun.
• All paints shall be thoroughly stirred with clean stick before use. While being used
the paint shall be stirred often to keep the pigment in uniform suspension. Ready
mix (factory mixed) paints only shall be used unless other types are specifically
mentioned. Sample colour boards shall be prepared by the contractor and got
approved by the Engineer before painting is started.
11.13.1.2 Brushes:-
• Unless other methods of application like spraying are specified paint shall be
applied with brushes. On no account shall rags be used in the application of paints.
• The size of brushes to be used for painting of various works shall be got approved
by the Engineer. All brushes shall be either round or oval shaped. Flat brushes when
specially authorized by the Engineer in writing shall not be over 8mm wide.
11.13.1.3 Containers:-
• The paint while being applied shall be kept in shallow pans and not in deep cans
and must be kept well stirred. All cans must be cleaned out at the end of each day's
work.
11.13.1.4 Scaffolding:-
• Scaffolding required for facility of construction shall be provided by the contractor
at his expense.
• Scaffolding will be double or single as it is warranted for the particular class of
masonry. But the ends of the poles should not be placed in the position of header
stone.
• Scaffolding shall be erected with steel sections or pipes, bullies or bamboos of
adequate strength so as to be safe for all constructions operation. The contractor
shall take all measures to ensure the safety of the work and working people. Any
instructions of the Engineer in this respect shall also be complied with.
468
• The contractor shall be entirely responsible for any damage to property or injury to
persons resulting from ill erect scaffolding, defective ladder and materials or
otherwise arising out of his default in his respect. Proper scaffolding shall be
provided to allow easy approach to every part of the work. Overhead work shall
not be allowed.
• Put log holes shall be made good by stones to match the face work when scaffolding
is being removed after ensuring that all holes behind are solidly filled with 1:4:8
cement concrete.
• Clauses of the General Specifications shall be applicable in all pertinent points to
the specifications for all classes of masonry.
11.13.1.5 Cleaning:-
removed by cleaning will not come in contact with freshly applied paint. The
method to be applied for cleaning and preparing surfaces for painting shall be
11.13.2 Painting Plastered surface – In addition to specifications for oil painting

general the following shall also apply for painting plastered surface.
1) New plaster shall not be painted till it is completely dry and hard
2) Preparation of the surface- The surface shall be carefully rubbed smooth and
thoroughly cleaned with the clean freshwater. Supplementary specification if any,
will be laid down in the special provision for the item according as the particular
nature of the surface to be paintedrequires.The surface shall be dry, smooth, clean
and free from dirt.
3) Priming coat - this shall consist of equal part of white and red lead mixed in boiled
linseed oil to the required consistency applied uniformly over the surface. When
this coat is dry,allcracks, holes and other such defects shall be filled with a mixture
of one-part white lead and three-part ordinary putty.The surface shall then be
rubbed down with sand paper and dusted clean.
4) Finishing coat -It may necessary to give two coats of paints. the first coat shall be
thin so that plaster may be thoroughly saturated the last coat shall be specified for
each item of painting.
5) The paint shall be applied with brushes it shall be sprayed as smoothly as possible.
6) The finishing shall be done with the paint of the colour and shade approved by the
engineer. The number of finishing coats shall be as mentioned in the item. The
paints used shall conform to the relevant Indian standard
469
11.13.2.1Application:-
• The paints shall be applied as soon as possible after the surface has been cleaned
before the deterioration of the surface by rust (in case of Steels faces) and
contamination of the surface by dust, dirt or any other foreign material for all
surfaces.
• Preferably painting should be done immediately after cleaning on the same day. If
rusting occurs after the surface is prepared for the there is contamination of cleaned
surface with salt, acid, alkali or other harmful materials before the priming coat is
applied and between the application of the remaining coats of paint, the surfaces
shall be cleaned again.
shall be applied with brush. Paint shall be worked into all crevices and corners
where possible and surface not accessible to accessible to brushes shall be painted
by sheepskin or spray or any other method approved by the Engineer. All runs or
sags shall be brushed out. Painting shall be done in a neat and workmanlike manner.
• The number of paint coat shall be as specified for the particular item.
• Sufficient time shall be allowed for one coat of paint to dry before the next is
applied.
11.13.3 GENERAL:-
priming coat.
Engineer.
11.13.3.1 Items to include:- The rate of the items include all labour, material and use of
1. Preparing the surfaces including knotting for receiving paint and finishing coats.
2. Scaffolding including its erecting and dismantling.
470

471
Providing and applying two coats of flat oil paint of approved colour to the old
structural steel work and iron work previously painted including scaffolding if
necessary, clearing & preparing surface excluding primer coat etc. Complete as
(IS - 1477 (Part-1) 1959,

11.14.1.1 Oil Paints:-
• The specifications cover the requirement for oil paint to be used as a finishing
material with respect to its composition, form, condition and tests to be carried out.
Unless expressly permitted in the special provisions or directed by the Engineer,
nothing but readily mixed (factory mixed) paint satisfying the I.S. specifications
for the particular paints shall be used.
• All paint, thinners etc. should be preferably be kept in a separate store that is well
• All paints shall be thoroughly stirred with clean stick before use. While being used
the paint shall be stirred often to keep the pigment in uniform suspension. Ready
mix (factory mixed) paints only shall be used unless other types are specifically
mentioned. Sample color boards shall be prepared by the contractor and got
approved by the Engineer before painting is started.
11.14.1.2 Brushes:-
• Unless other methods of application like spraying are specified paint shall be
applied with brushes. On no account shall rags be used in the application of paints.
• The size of brushes to be used for painting of various works shall be got approved
by the Engineer. All brushes shall be either round or oval shaped. Flat brushes when
specially authorized by the Engineer in writing shall not be over 8mm wide.
11.14.1.3 Containers:-
• The paint while being applied shall be kept in shallow pans and not in deep cans
and must be kept well stirred. All cans must be cleaned out at the end of each day's
work.
11.14.1.4 Scaffolding:-
• Scaffolding required for facility of construction shall be provided by the contractor
at his expense.
• Scaffolding will be double or single as it is warranted for the particular class of
stone.
• Scaffolding shall be erected with steel sections or pipes, bullies or bamboos of
adequate strength so as to be safe for all constructions operation. The contractor
instructions of the Engineer in this respect shall also be complied with.
472
• The contractor shall be entirely responsible for any damage to property or injury to
not be allowed.
• Put log holes shall be made good by stones to match the face work when scaffolding
is being removed after ensuring that all holes behind are solidly filled with 1:4:8
cement concrete.
• Clauses of the General Specifications shall be applicable in all pertinent points to
11.14.1.6 Protection:-
Painted surface shall be protected from sun, rain, condensation,
11.14.2 Painting iron and steel work – In addition to specifications for oil painting
general the following shall also apply for painting iron and steel work.
Operation and workmanship for painting iron and steel work shall be as per
as 1477 (Part-1) 1959, Code of practice for finishing of Iron and Steel, paintings
and allied finish is subjected to following:-
1) The method of preparation of the surface for painting shall be as specified in the
special provisions for each item and as Cleaning mentioned above. Where iron and
steel works need repainting instructions details in class 8 of 1477 (Part-1) 1959,
shall be followed.
2) Intermediate protective treatment (Pre-treatments) shall be omitted, unless
specified in the special provisions.
3) The finishing court shall be of the tent at specified for each item by the engineer.
The number of finishing coats of the required shade of colour shall also be specified
for each item separately. They shall be two when the number is not specified.
4) Actual date of painting girders, Steel tanks and other steel structures shall be neatly
marked by the contractor on the structure according to the instructions of the
engineer.
5) For the repainting necessitated due to any specific reason the relevant instructions
given in clause 8.3 of i.s. 1447 (Part I)-1959 shall be followed.
473
6) The finishing shall be done with the paint of the colour and shade approved by the
engineer. The number of finishing coats shall be as mentioned in the item. The
paints used shall conform to the relevant Indian standard
• The paints shall be applied as soon as possible after the surface has been cleaned
before the deterioration of the surface by rust (in case of Steels faces) and
contamination of the surface by dust, dirt or any other foreign material for all
surfaces.
• Preferably painting should be done immediately after cleaning on the same day. If
rusting occurs after the surface is prepared for the there is contamination of cleaned
surface with salt, acid, alkali or other harmful materials before the priming coat is
applied and between the application of the remaining coats of paint, the surfaces
shall be cleaned again.
• The number of paint coat shall be as specified for the particular item.
• Sufficient time shall be allowed for one coat of paint to dry before the next is
applied.
11.14.3 GENERAL:-
priming coat.
Engineer.
474
11.14.3.1 Items to include:-
The rate of the items includes all labour, material and use of tools necessary
to carry out the following operations:-
1. Preparing the surfaces including knotting for receiving paint and finishing coats.
2. Scaffolding including its erecting and dismantling.

The contract rate shall be per unit of one square meter of painted surface.
The linear dimension shall be measured correctly up to 2 places of decimal of
meter. The area shall be worked out correct up to 2 places of decimal of the square
meter.
475
Providing and applying two coats of lead / zinc base oil paint / bituminous paint of
approved colour and shade to wood work/fiber boards previously painted including
scaffolding if necessary, preparing surface excluding primary coat etc. complete as
Material And Accessories:-
11.15.1.1 Oil Paints:- The specifications cover the requirement for oil paint to be used as a
finishing material with respect to its composition, form, condition and tests to be
carried out. Unless expressly permitted in the special provisions or directed by the
Engineer, nothing but readily mixed (factory mixed) paint satisfying the I.S.
specifications for the particular paints shall be used.
All paint, thinners etc. should be preferably be kept in a separate store that is well
All paints shall be thoroughly stirred with clean stick before use. While being
used the paint shall be stirred often to keep the pigment in uniform suspension.
Ready mix (factory mixed) paints only shall be used unless other types are
specifically mentioned. Sample colour boards shall be prepared by the contractor
and got approved by the Engineer before painting is started.
11.15.1.2 Brushes:- Unless other methods of application like spraying are specified paint
shall be applied with brushes. On no account shall rags be used in the application
of paints. The size of brushes to be used for painting of various works shall be got
approved by the Engineer. All brushes shall be either round or oval shaped. Flat
brushes when specially authorized by the Engineer in writing shall not be over 8mm
wide.
11.15.1.3 Containers:- The paint while being applied shall be kept in shallow pans and not
in deep cans and must be kept well stirred. All cans must be cleaned out at the end
of each day's work.
111.15.1.4 Scaffolding:- Scaffolding required for facility of construction shall be provided
by the contractor at his expense.
Scaffolding will be double or single as it is warranted for the particular class of
stone. Scaffolding shall be erected with steel sections or pipes, bullies or bamboos
of adequate strength so as to be safe for all constructions operation. The contractor
instructions of the Engineer in this respect shall also be complied with. The
contractor shall be entirely responsible for any damage to property or injury to
not be allowed.
476
Put log holes shall be made good by stones to match the face work when
scaffolding is being removed after ensuring that all holes behind are solidly filled
with 1:4:8 cement concrete.
Clauses of the General Specifications shall be applicable in all pertinent points to
11.15.2 Precautions in using lead paints:-

1. White lead, sulphate of the lead and all products containing those pigments (but not
while pigments containing not more than 2% of lead) shall not be used in internal
painting, except for priming coat and artistic painting or fine lining work. They
shall be as far as possible used in painting operations in the form of paste or ready
mixed paint and measures shall be taken wherever practicable, to prevent danger
arising from the application of the paint in the form of spray or by dust caused by
rubbing down and scraping.
2. Paint workers must be wanted to avoid getting smeared with the above paints.
11.15.2.1 Cleaning:- Cleaning operations shall precede painting so that paint may be
applied to clean surfaces. The work shall be carried out in such a manner that the
dirt and matter removed by cleaning will not come in contact with freshly applied
paint. The method to be applied for cleaning and preparing surfaces for painting
shall be mentioned in the specifications for each type of surface. When not so
mentioned, any suitable method approved by the Engineer for exposing the original
surface without damage shall be adopted.
11.15.2.2 Application:-The primer coat of the paints shall be applied as soon as possible after
the surface has been cleaned before the deterioration of the surface by rust (in case
of Steels faces) and contamination of the surface by dust, dirt or any other foreign
material for all surfaces. Preferably painting should be done immediately after
cleaning on the same day. If rusting occurs after the surface is prepared for the there
is contamination of cleaned surface with salt, acid, alkali or other harmful materials
before the priming coat is applied and between the application of the remaining
coats of paint, the surfaces shall be cleaned again.
Paints shall not be applied when the air is misty or atmospheric conditions are
such as to promote condensation or in the opinion of the Engineer, the conditions
are otherwise unsatisfactory for the work. Painting shall normally be done only in
dry weather. It shall not be applied upon damp and moist surfaces.
Paint may be applied by spraying or brushing. Unless and otherwise specified
paint shall be applied with brush. Paint shall be worked into all crevices and corners
The number of priming and finishing coat shall be as specified for the particular
item.
Sufficient time shall be allowed for one coat of paint to dry before the next is
applied.
477
11.15.3 GENERAL:-
priming coat.
Engineer.
1. Supplying the approved oil paint for priming and finishing Coat
coats.

478
Providing and applying coal tar in one coat on previously painted wood work
including preparing the surface scaffolding etc. Complete as directed.
(Item No. MR 16)

Use a hook scraper, putty knife or sanding tool to remove the loose old
paint. If the old wood surface is covered with many layers of paint and varnish
then scrape the layers down to bare wood.
11.16.1.1 Material –
Coal tar blended with polyamide curing agent along with suitable amount of
pigments solvent and thixotropic additives &turpentine.
Cleaning operations shall precede painting so that paint may be applied to clean
• The primer coat of the paints shall be applied as soon as possible after the surface
has been cleaned before the deterioration of the surface by rust (in case of Steels
faces) and contamination of the surface by dust, dirt or any other foreign material
for all surfaces. Preferably painting should be done immediately after cleaning on
the same day.
• The number of priming and finishing coat shall be as specified for the particular
item. Sufficient time shall be allowed for one coat of paint to dry before the next
is applied.
479
11.16.2 GENERAL:-
Engineer.
coats.

480
Applying geru wash and white wash to canal road side Km stones/Boundary stones /
Ch. stones / bottom of trees, etc. Complete as directed.(Item No.MR 17)
11.17.1 GENERAL:-
The item refers to white-washing over old and new concrete, Stonemasonry
brick or plastered surfaces and asbestos cement sheets.

11.17.2.1 White-wash.-
• White-wash shall be prepared from fresh burnt white stone lime or shell lime. This
lime shall be of class C type as given in specification No. A. 1. Surkhi lime or lime
of equivalent quality may be used.
• The lime shall be dissolved in a tub with sufficient quantity of water (about 4.5
litres/kg. of lime) and the whole well and thoroughly mixed and stirred until it
attains the consistency of thin cream. The wash shall be taken out in small quantities
and strained through a clean course cloth.
• Application of white-wash.-On the surface so prepared, the white-wash shall be
laid. Each coat shall be laid on with a brush. The first stroke of the brush shall be
from the top downwards, another from bottom upwards over the first stroke, and
similarly, one stroke from the right and another from the left over the first brush
before it dries.
• This will form 1 coat. Each coat must be allowed to dry and shall be subject to
inspection before the next coat is applied.When dry, the surface shall show no signs
of cracking.
11.17.2.2 Item to include.-The rate shall include all labour, materials, equipment
anddevices to carry out the following operations
(1) Scaffolding including erection and removal.
(2) Providing and preparing the white wash.
(3) preparing the surface for white wash including the scaffolding,
(4) Applying the white wash in requirednumberof coats as specified above and prior
white washing of repaired patches.
11.17.3 MODE OF MEASUREMENT AND PAYMENT-

The measurement shall be recorded on number basis and Payment will be
made on no of trees and stones at the specified rate agreed in the Schedule b of the
tender.
481
Removing M.S. needles from the K.T. Weir opening before on set of the monsoon for
Passing the flood water through the K.T. Weir openings including conveying the same
up to the river banks, stacking the same as directed with all leads and lifts etc.
complete as directed.(Item No. MR 18)

The item included the removing the M.S. / Fiber needles by standing or
sinking in the water as and when required with all leads and lifts. The removed
needle should be properly stacked as site, as directed by the Engineer - in charge.
No losses shall be accepted. The job should be made at the risk of the contractor.
Any mispher / injury is contractor's responsibility.
11.18.2 Mode of measurement and Payment –

made on no of needles at the specified rate agreed in the Schedule b of the tender.
482
Transportation of M.S.Needles from the river bank to the store shed / safe place or
from store shed/safe place to river bank by Bullock cart including loading unloading
and stacking as directed with all leads and lifts etc. complete as directed. (lead half
Km)(Item No. MR 19)
11.20 Description of item:-

Providing supplying and applying 1 coats of red oxide to the steel structure as a
primary coat including cleaning, scrubbing for preparing the surface to apply paint
with all lift etc complete as directed.(Item No. MR 20)
11.20.1 Scope of work:

Providing and applying one coats of red oxide paint to steel needles
including conveying from stack including removing dirt and other foreign material
with wire brushes, scrapping with and para etc. complete and restacking after paint.
The item shall comply the Standard specification (Red booklet 1972 , Edition )
Volume –II / page No. 406 –BdO-6.
11.20.2 Mode of measurement and Payment –

The measurement shall be recorded on square meter basis and payment will
be made on square metre of needles of primer red oxide paint. The linear
dimensions shall be measured correct upto two places of decimal of metres. The
area shall be worked out correct upto two places of decimal.
483
Fixing of M.S. Needles in weir openings after offset of the monsoon for storage of
Water from post monsoon river flow and making it water tight by using wooden pegs,
Dungry cloth & empty cement bags etc. with all leads & lifts and including all material
and labour etc. complete as directed. (For 07 Nos)(Item No. MR 21)

• The item includes fixing the M.S needless with all leads and lifts.
• The needles should be fixed in the grooves provided for storage of water from post
monsoon river flow and making it watertight by using cement mortar, wooden pegs,
dungry cloth and empty cement bags.
• There should not be any gap in between fixed needles in row. If a gap is formed the
needle should be replaced to match in the other needles while fixing needles. If any
needle flows the water, the same should be fixed in the grooves for which no claim
is acceptable .
• The fixing should be done carefully to avoid any injuries to the labourers .The
labours engaged on this work must know swimming in the flowing water of the
river / stream. The fixing job should be done as per the requirement of the
department at any time of the day.
11.21.2 MODE OF MEASUREMENT AND PAYMENT –

484
Cleaning by redrilling the vertical porous drain pipe including removing of leaching
material, grout material if any inside of the V.P.D. etc complete with all leads and lifts
etc. as directed. (Vertical upward drilling)(Item No. MR 22)
a) From 0 to 5 m.
b) From 5 to 10 m.
c) From 10 to 15 m.
d) From 15 to 20 m.
11.22.1 GENERAL :
Cleaning by re-drilling the porous / drain pipe including removing of
leaching material, grout material if any inside the vertical porous pipe etc complete
with all leads and lifts.(vertical upward drilling including cleaning & flushing the
drilled holes, conveyance of all material &equipments for other ancillary operation
etc complete.)
This item provides for cleaning of formed vertical porous drains by taking
vertical inverted re-drilling from inspection gallery and from foundation gallery
with diamond drilling machine using NX bit with double tube core barrel system.
It shall comply with IS 6926-1996, including cleaning & flushing the drilled holes,
conveyance of all material &equipments for other ancillary operation etc complete.
11.22.3 WASHING OF HOLES:

On completion of the drilling of a hole, the holes should be washed by
allowing the drilling water to run until the return from the hole is reasonably clean.
11.22.4 CARE TO BE TAKEN:

11.22.4.1Care shall be taken to avoid clogging of the pipes during progress of work.
11.22.4.2 Any VPD become clogged or obstructed from any cause before final acceptance
of the works, it shall be cleaned out in a manner approved by the Engineer-in
charge.
11.22.4.3Cleaning of VPD shall be taken in hand after completion of grouting work in that
monolith.
11.22.4.4At most care shall be taken while re-drilling of VPD so that there should not be
any damages to the existing dam masonry.
11.22.4.5Any damages caused to the dam structure shall be recovered from the contractors.
11.22.4.6Engineer-in charge shall insure the actual length of re-drlling.Any payment shall
be made accordingly.
11.22.4.7All the holes re-drilled shall be truly vertical to avoid any damages to the structure.
485
11.22.4.8All the necessary arrangement for lighting and ventilation shall be done by the
contractor.

The contract rate shall be for one running meter length of Re-drilling as
specified. The rate shall include Re-drilling of holes and maintaining the hole free
from leaching material. Measurement for the work shall be done on the basis of
actual depth of Re-drilled hole measured from initial RL of drilling to final depth
by linear measurement but not by difference in RL. Partly drilled holes which in
the opinion of the Engineer-in-charge are not useful AND will not be measured at
all.
486
Providing and applying single coat of epoxy primer (4.42 sq m per kg) (resin :
hardener, 2:1) on old UCR / concrete surface etc. Complete as directed. (Item No. MR
23)
Providing and applying epoxy compound
11.23.1 Scope of Work:-
The item shall include application of primer and coat of epoxy compound
manufactured by Dr Beck and Co., India Ltd. (Dobeckot epoxy resin system) on
old UCR/Concrete including necessary scaffolding, preparation of surface as
directed by Engineer-in-charge
11.23.2 Material
The material tube used shall be of following make and in the proportion given
against the same.
11.23.2.1Material required for filling cavities and gap in concrete for pressurized box.
i) Debeckot 505 C 100 parts by weight.
ii) Hardner EH 411 50 parts by weight.
iii) Silica Sand M-10 600 parts by weight

11.23.2.2Material required for primer coat
i) Dobeckot 5022 100 parts by weight
ii) Harner EH 408 55 parts by weight
11.23.3 Properties
Debeckot epoxy resin shall have the following properties.
Sr. Property 505 C + EH 411 + M10 5022 + EH 408
No (Mortar)(Silica sand) (coating)
1. Compressive Strength 720 kg/sqcm 1300 kg/sqcm.

2. Flexural strength 230 kg/sqcm 750 kg/sqcm.
3. Tensile strength 150 kg/sqcm 430 kg/sqcm.
4. Hardness shore D 82 77
5. Pot life 135 min at 75 min at
Room temp. (R.T.) (R.T)
6. Full curing 1 to 7 days at R.T. 1 day at R.T.
11.23.3.1The epoxy material shall be recent make having minimum 10 months pot life in
balance at the time of use. The material should be brought in original packing with
487
seals intact. The epoxy resins and hardeners once opened shall be fully consumed
in shortest possible time.
11.23.3.2 Brushes
The epoxy coating should be applied by stiff nylon bristle brush recommended by
the manufacturers and approved by Engineer-in-charge.
11.23.3.3 Scaffolding :
The scaffolding, if necessary, shall be provided as specified in standard
specifications of P. W. Dept. B. 9.11.
11.23.4 Preparation of Surface
All dirt, dust oil, grease, algae or any other substances likely to impair good
bonding should be removed from surface by scrubbing or using some detergent and
washing it with clean water. All loose and spoiling concrete pieces shall be
removed. The surface to be coated shall be thoroughly roughened and got approved
from the Engineer-in-charge.
The epoxy resins and hardeners brought to site shall be stored as specified by
the manufacturer at room temperature (20 degree - 30 degree C) and away from
direct sunlight. Resins and hardeners shall be stored separately. Only skilled and
experienced workers shall be entrusted with the application of epoxy compounds.
Rubber or polyethylene gloves must be worn by workers handling resin products.
Tools and mixing equipments shall be cleaned immediately after use by using
scrapper and solvents like xylene. All handling precautions specified by
manufacturer shall be strictly observed.
11.23.4.1 Mixing
The contractor shall employ only skilled and experienced workers for
preparation of epoxy compound. The mixing proportion of epoxy dobeckot and
hardener as specified for material. Exact proportion shall be applied by weight of
specified by the manufacturer and approved by Engineer-in-charge.
11.23.4.2 Application
Prior to application of primer coat the cavities and unevenness shall be filled
up with epoxy resin putty. The primer coat shall be applied by means of brushes
after preparation of surface a primer coat as specified in para 1.5 shall be applied
and cured. The consumption of materials shall be as given below.
i) For primer 0.35 to 0.50 kg/sq.m.
11.23.5 Mode of Measurement and Payment

The measurements shall be in the square metre. The rate shall be on the square
metre basis. The rate shall include the cost of scaffolding etc.
488
Providing & applying of Epoxy Mortar layers to Monolith joint of Masonry Dam with
all lead & lift etc. complete as directed.(Item No. MR 24)
PROVIDING AND APPLYING EPOXY COMPOUND
11.24.1 Scope of Work:-

Epoxy bonded epoxy mortar should be used where the depth of repair is
less than 1-1/2 inches and the exposure conditions are such that relatively constant
temperatures can be expected. Epoxy mortars have thermal coefficients of
expansion that may be significantly different from conventional concrete. If such
mortars are used under conditions of wide and frequent temperature fluctuations,
they will cause failure just below the bond surface in the base concrete.
The item shall include application of primer and coat of epoxy compound
manufactured by Dr Beck and Co., India Ltd. (Dobeckot epoxy resin system) on
old UCR/Concrete including necessary scaffolding, preparation of surface as
directed by Engineer-in-charge
11.24.2 Material
The material tube used shall be of following make and in the proportion given
against the same.
11.23.2.1Material required for filling cavities and gap in concrete for pressurized box.
i) Debeckot 505 C 100 parts by weight.
ii) Hardner EH 411 50 parts by weight.
iii) Silica Sand M-10 600 parts by weight
11.24.2.2Material required for primer coat

i) Dobeckot 5022 100 parts by weight
ii) Harner EH 408 55 parts by weight
11.24.2.3 Material required for top coats.

i) Dobeckot 505 C 100 parts by weight
ii) Hardner EH 408 50 parts by weight

100 parts by weight
iii) Silica filler 53
489
11.24.3 Properties
Debeckot epoxy resin shall have the following properties.
Sr. Property 505 C + EH 411 + M10 5022 + EH 408
No (Mortar)(Silica sand) (coating)

.
1. Compressive Strength 720 kg/sqcm 1300 kg/sqcm.
2. Flexural strength 230 kg/sqcm 750 kg/sqcm.
3. Tensile strength 150 kg/sqcm 430 kg/sqcm.
4. Hardness shore D 82 77
5. Pot life 135 min at 75 min at
Room temp. (R.T.) (R.T)
6. Full curing 1 to 7 days at R.T. 1 day at R.T.
11.24.3.1The epoxy material shall be recent make having minimum 10 months pot life in
balance at the time of use. The material should be brought in original packing with
seals intact. The epoxy resins and hardeners once opened shall be fully consumed
in shortest possible time.
11.24.3.2 Brushes
The epoxy coating should be applied by stiff nylon bristle brush recommended by
the manufacturers and approved by Engineer-in-charge.
11.24.3.3 Scaffolding :
The scaffolding, if necessary, shall be provided as specified in standard
specifications of P. W. Dept. B. 9.11.
11.24.4 Preparation Of Surface

All dirt, dust oil, grease, algae or any other substances likely to impair good
bonding should be removed from surface by scrubbing or using some detergent
and washing it with clean water. All loose and spoiling concrete pieces shall be
removed. The surface to be coated shall be thoroughly roughened and got
approved from the Engineer-in-charge.
The epoxy resins and hardeners brought to site shall be stored as specified by the
manufacturer at room temperature (20 degree - 30 degree C) and away from direct
sunlight. Resins and hardeners shall be stored separately. Only skilled and
experienced workers shall be entrusted with the application of epoxy compounds.
Rubber or polyethylene gloves must be worn by workers handling resin products.
Tools and mixing equipments shall be cleaned immediately after use by using
scrapper and solvents like xylene. All handling precautions specified by
manufacturer shall be strictly observed.
490
11.24.4.1 Mixing
The contractor shall employ only skilled and experienced workers for preparation
of epoxy compound. The mixing proportion of epoxy dobeckot and hardener as
specified for material. Exact proportion shall be applied by weight of specified by
the manufacturer and approved by Engineer-in-charge.
11.24.4.2 Application
Prior to application of primer coat the cavities and unevenness shall be filled up
with epoxy resin putty. The primer coat and two top coats shall be applied by
means of brushes after preparation of surface a primer coat as specified in Para 1.5
shall be applied and cured. The consumption of materials shall be as given below.
i) For primer 0.35 to 0.50 kg/sq.m.
ii) For top coat 0.39 to 0.35 kg/sqm.
11.24.5 Mode of Measurement and Payment

The measurements shall be in the kg/square meter. The rate shall be on the square
meter basis. The rate shall include the cost of scaffolding etc.
491
Providing,erecting,testing and commissioning of a Casagrande type Piezometer in a
100 mm dia.cased drilled hole with all its required accessories as follows as per IS -
7356 part-I at the dam site(ITEM NO MR 27)
Piezometers are devices used to measure the water pressure at specific locations
in dam bodies, foundations, and abutments. For fine-grained soils with low
permeability, a Casagrande open piezometer is often installed in a borehole in the
foundation or in the dam’s embankment. The internal plastic piezometer tube
emerges at the ground surface and, if the pressure of pore water in the tube is lower
than the level of the embankment, the height of water in the piezometer (pore
pressure) is measured using an ordinary electric probe. If the phreatic level is
above the embankment surface, the tube is extended vertically above the ground
level. This type of piezometer is readily installed in existing dams and is simple to
use, reliable, and inexpensive. It is most suitable where the phreatic surface does
not change much. The main shortcoming of open standpipe piezometers is the
need for a discharge of water to or from the tube for it to adapt to pore pressure
changes. Because of this, there is a noticeable time lag in recording the pores
pressure changes if they occur quickly.
11.25.1 Material:-
1) 37 mm dia,6 mm wall thick and 60 cm long porous tube piezometer with stopper
and top adapter made up of carborendum with porous tube filter of grain size 60
micron as specified in IS 7356 part-I.
2) PVC riser pipe of 12mm outer dia,1.5 mm wall thickness and 1.5m long
3) PVC socket for riser pipe joint.
4) 12 mm brass hexagonal pipe top cap.
5) 50 mm dia and 1.25 m long G.I pipe casing protective cover
6) 150 mm dia and 1.20 m deep well graded sand filter around the Casagrande
piezometer.
7) 50 mm dia and 1.00 m deep bentonite clay plug above sand filter
11.25.2 Installation-
Installation of the Casagrande type Piezometer is to be carried out under the
supervision of the engineer in charge and as directed by the engineer in charge.
Refer IS code IS:7356 part-I Code of practice for Installation of Casagrande type
Piezometer.
492
11.25.3 Mode of Measurement & Payment:-
Main Item is Split up in Sub components as part execution for which job rate
is specified in CSR .Executed Quantity shall be recorded and pay accordingly.
493
Providing electronic water level indicator for taking water level reading in
Casagrande piezometer with stainless steel probe connected with indelibly graduated
electric measurement cable having graduation at 0.5 m interval & 200 m length (100
m on spool with the device and 100 m as spare ) as per IS 7356 (Part I) 2002 (ITEM
NO MR 28)
It comprises of two insulated wires passing through a probe of 6 mm

diameter of suitable material. The lower ends of wires shall be bare for contact
with water. The water level sounder is required to be lowered from the surface into
the PVC tube with the help of the connecting graduated cable for taking
observations. Suitable markings should be given on the cable preferably at 0.5 m
intervals with an arrangement to measure levels to accuracy of 2 mm. The length
of the wires should be commensurate with depth up to which the observations are
required to be made. The sounder unit should be battery operated, complete with
reel/spool, cable extension rod of 0.5 m length, leather carrying case, tripod stand
and dummy probe with nylon cord of 50 m length. The unit should also be
equipped with battery operated indicator and buzzer
11.26.1 Material–
1) flexible tape about 200 mtr
2) Stainless steel probe of 6 mm diameter.
Installation of the electronic water level indicator is to be carried out under
the supervision of the engineer in charge and as directed by the engineer in charge.
Refer IS code IS:7356 part-I Code of practice for Installation of electronic water
level indicator.
11.26.3 Mode of Measurement& Payment: -

Main Item is Split up in Sub components as part execution for which job
rate is specified in CSR .Executed Quantity shall be recorded and pay accordingly.
494
Providing, erecting, testing and commissioning of Twin Tube Piezometer with all its
required accessories as per IS 7356 part -II with all material ,labour and
transportation at the sites etc complete.(ITEM NO MR 29).
11.27.1 Material –
1)foundation or embankment type twin tube piezometer tip assembly of 50 mm
dia and 32 mm height with all its accessories like metallic o ring ,ceramic filter
and screws etc complete.
2) Polypropelene tubing 8 mm O.D. 1.6 mm wall thickness which can be fitted to
the twin tube piezometer tip assembly with all relevant accessories like elbow,
nuts etc complete.
3) identification tag with nylon thread.
4) Brass compression connector between twin tube tip assembly and tubing.
5) Providing Brass End Plug
6) Twin tube piezometer manifold system in the Terminal Well like main Pressure
gauge, Valves, Pressure Pump Set etc. With all the required accessories as per IS
7356 Part II.
7) panel board with individual pressure gauges for six tips.
Two 8 mm OD x 1.6 mm wall thickness plastics (polypropylene) tubes

connect each piezometer tip with the recording gauges in the terminal well. Each
coil of tubing is normally 300 m long but since the piezometer tips may require
more than 300 m of tubing to connect them with gauges in the terminal well, the
lengths of the tubing needed for each tip should be estimated from the installation
drawing, after allowing for slack (1 to 1.5 m per 100 m length of
tubing),approximately 5 m for extensions in the terminal well and contingencies.
All tubes should be marked, coupled and recoiled prior to installation. Tubing
should be marked or identified with permanent markers every 15 m by the use of
plastics or metal bands stamped with appropriate piezometer numbers. Suitable
identifications should include the piezometer number and an ‘I’ or ‘O’ to indicate
inlet or outlet tubes. The use of adhesive tapes to hold the identification is not
recommended because moisture can loosen the adhesive. Temporary identification
may be obtained by writing the number of tip and identification on a strip of paper
and covering with transparent plastic tape. Permanent identification is necessary
to prevent errors in making up to proper terminal well connections, and to ensure
correct splicing if the tubing is accidentally cut or broken. Tubing extruded from
plastic materials such as polyvinylidine chloride (PVNC) and from various
thermoplastic has no field solvent and generally cannot be cemented. Lengths of
tubing are, therefore, connected by compression type brass couplings. A special
brass insert should be installed at the end of the plastic tubing to form a suitable
connection. assembly of a compression type connection between lengths of 8 mm
OD tubing suitable alternative compression joints may be used to couple the
tubing.
495
Installation of Twin Tube Piezometer is to be carried out under the
Refer IS code IS:7356 part-II Code of practice for Installation of Twin Tube
Piezometer
FIG .2 EMBANKMENT TYPE

PIEZOMETER TIP (WITH CERAMIC
DISC )
11.27.3 Mode of Measurement &Payment:-

496
11.28 Description of Item:-
Providing accessories required for Repairs to manifold system of twin tube
piezometer as below as per IS 7356 PART- II (ITEM NO MR 30).
11.28.1 Material :-
1) Compression type T
2) Straight union for joint
3) Elbow brass fitting
4) Ferrule and nut
5) Compression type Brass coupling for jointing tubes End Plug
6) End Plug
7) Gauge Plug
8) Hand shut up valve
9) Pressure Pump
10) Identification Tag
All the accessories required as per demand for replacement of faulty,
damaged item for repairs as per IS 7356 part II in terminal well of twin Tube
piezometer.
Installation of Twin Tube Piezometer is to be carried out under the
Refer IS code IS:7356 part-II Code of practice for Installation of Twin Tube
Piezometer.
11.28.3 Mode of Measurement& Payment: -

rate is specified in CSR .Executed Quantity shall be recorded and pay
accordingly.
497
Manufacturing, Supplying and Erection of sub assemblies of conventional plumb
bob as per IS 13073 (part I) : 2002(ITEM NO MR 31)
11.29.1 - MATERIAL :-
a) Table & stand
Table & stand of size 700 x 700 mm & 1200 mm height having
arrangement for fitting the microscopes perpendicular to each other, as per site
requirement. For this purpose, the table is having top base with foot screws for
vernier micro scope to maintain the level. It is necessary for microscope to be in
perfect horizontal level at all time. Four legs of stand are made up of angle 50x 50
x 5 mm thick, & top frame, of size 700 x 700 mm made from 35 x 35 x 5 mm
thick angle, as to support a base plate for fitting of microscope with complete
finishing, champhering, buffing as per specifications given bellow
1) SS 304 grade angle 50 x 50 x 5 mm in size and 1200 mm in length, 4 Nos.
for legs of stand.
2) SS 304 grade angle 35 x 35 x 5 mm size 700 mm long – 4 Nos.
3) SS 304 grade bar of dia. 12 mm or angle of size 25 x 25 and 5 mm thick &
700 mm in length 4 nos. each as bracing to stand to be welded at 200 mm distance
from bottom of stand.
4) SS 304 grade plate 700 mm x 700 mm & 4 mm thick.
5) Foot screw for vernier microscope having dia. of 5 mm grove at top -6 nos.
Complete job including material ,labour charges.
b) Weight gatta.
Weight gatta with complete finishing, champhering, buffing as per specifications
given bellow.
1) SS 304 grade bar of ø50 mm & 130 mm long having a base plate of ø 100 mm
& 5 mm thick welded at bottom &having a blind threaded hole ø 25 mm & 40
mm long at top.
2) SS 304 grade plates ø 260 x 25 mm thick – 3 Nos. having central hole of 50
mm as per drawing.
3) Top cap screw of ø 25 mm & 15 mm long with rectangular head 30x50 mm x
4 mm thick with through hole of 2 mm.
c) Anchoring arrangement for fix point .

Fixing point anchoring arrangement, to make rigid & firm fixing point .It
consists of the channel 125x 65x 5 mm and 1000 mm length as a base welded
by 35 x 35 x 5 mm angle as support to frame , ‘I beam’ welded perpendicularly
on this structure. Angle of 65 x 65 x5 mm welded perpendicular to I beam to make
provision for drum assembly as shown in drawing. The SS plate of size 200 x
200 x 05 mm thick having hole of 12 mm & bonnets screw to anchor the wire is
placed between C channel and I Channel ,with complete, champhering, finishing,
buffing etc. as per speciation given below.
1) SS 304 grade C channel of size 125 x 65 x 5 mm thick & 1000 mm in length- 2
nos.
498
2) SS 304 grade I Channel of size 125 x 75 x 5 mm thick & 250 mm in length – 2
Nos.
3) SS 304 grade angle 35 x 35 x 5 mm thick 250 mm in length - 2 Nos.
4) SS 304 grade angle 65 x 65 x 5 mm thick, 350 mm in length – 2 Nos.
5) SS 304 grade drum of dia of 50 mm & 100mm in length as per drawing
6) SS 304 grade plate 200 x 200 x 05 mm thick having hole of dia. of 12 mm with
bonnets screw .
7) SS 304 grade bonnet screw of dia. 25 mm & 40 mm in length having thread on
20 mm length with lock screw & through hole of 1.8 mm at center. Complete
job including material ,labour charges.
d) Oil tank & stand for tank.

Oil tank & stand for tank made form SS 304 grade with complete finishing,
champhering, buffing etc. as per specification given bellow .
Size of tank 500 x 500 mm at base & 400 mm height mode form SS 304
grade plate 1 mm thick.
1) Trapezoidal cover to above tank with locking arrangement at top made from SS
304 grade plate 1 mm thick.
2) Stand for tank of size 525 x 525 & 400 mm in height made from SS 304 grade
angle 35 x 35 x 5 mm
3) Supply of S.S. wire ø 1.6 x 100 mtr long.
4) Manufacturing of Box Cover of size 400 x 400 x 250 for Microscopes 2 Nos.
5) Vernier microscope- which is having 18 cm scale in size, Horizontal scale Least
count of 0.01 mm Vertical scale Least count of 0.01 mm. Microscope shall be of
20-21 power and focusing through 37 mm having cross hair in the eye piece.
Installation of conventional plumb bob is to be carried out under the

499
Manufacturing, supplying sub-assemblies of Inverted plumb bob as per IS 13073
(ITEM NO MR 32)
11.30.1:-
a) Stand for Oil tank of plumb bob
Stand for Oil tank of size 0.7 x 0.7 m and 1.8 m height made from SS 304
grade angle 65 x 65 x 5 mm with complete, finishing, champhering, buffing etc as
per specifications given bellow
1) SS 304 grade plate 700 x 700 x 4 mm thick
2) Supporting angles of SS 304 grade 35 x 35 x 5 mm should be welded at top to
support diesel tank.
3) SS 304 grade angle 35 x 35 x 3 mm - 2 no welded at 0.6 m distance from top of
stand to support the plate 700 x 700 mm.
Supporting bracing of SS 304 grade angle 25 x 25 x 3 mm-4 nos. welded at 100
mm distance from bottom of stand.
b) Oil tank with cover

Oil tank of size 700 x 700 mm and 450 mm in height along with cover for
inverted type plumb bob with complete, finishing, champhering, buffing etc as per
specifications given bellow
1) Plate of tank -SS 304 grade plate 2 mm thick along with SS 304 grade plate
stiffeners 20mm width x 2 mm thick.
2) SS 304 grade pipe OD 110 mm x 1mm thick x 360 mm long and one end
covered with SS plate dia110 mm having hole of dia. 50 mm should be welded in
the tank centrally with other side open.
3) SS cover for diesel tank of size 700 x 700 mm with 25 mm side plates with
lifting arrangement.
4) Tank must be supported by three nos. of vertical stiffeners of 20 mm width 2
mm thick. Welded to each vertical face of diesel tank at equispaced distance.
5) Tank must be leak proof.
c) Copper/ SS float in Oil tank

cylindrical float of size OD 510 mm & ID 200 mm and 255 mm in height
made from 1 mm thick copper or SS 304 plate along with 3 nos of Clamps 50
mm long x 25 mm in width x 1mm thick duly brazed/welded at 120 degree and at
250 mm PCD on top face of float with complete, finishing, champhering, buffing
etc as per specifications given above.
500
d) Spider attachment
Manufacturing and supplying Spider attachment for inverted type plumb bob
with complete ,finishing, champhering, buffing etc as per specifications given
below .
1) SS 304 grade pipe dia OD 28 mm ID 25 mm internally threaded at both ends
upto 25 mm length , the pipe is 470 mm long .
2) Bonnet Screw dia 28 mm x 40 mm long having threding dia 25 m x 20 mm long
with radial locking screw and through hole of 1.8 mm at centre ,
3) Three nos of plates 240 x25 x 2 mm thick are welded at 120 degree to bonnet
screw.
4) Other end of pipe is locked by bonnet screw of same dimensions as above.
e) Anchor rod
Anchor rod with rough surface made from SS 304 grade dia 25 mm x 1 m long
with dia 40 mm x 4 mm th. plate welded at one end and rectangular notch of 20
mm length at other end with dia 1.6 mm through hole opening in notch with
complete ,finishing ,champhering, buffing etc .
f) SS wire ø 1.6x 100 m long

g) Acrylic sheets- 4 mm thick size 700 x 700 mm- 4 Nos.
h) Vernier Microscope - 18 cm, Least count of horizontal scale and vertical
vernier scale of 0.01 mm.
Installation of conventional plumb bob is to be carried out under the supervision of the
engineer in charge and as directed by the engineer in charge.

Main Item is Split up in Sub components as part execution for which job rate is specified in
CSR .Executed Quantity shall be recorded and pay accordingly.
501
For Office Use Only
Govt. of
Maharashtra Water
Resources Department
SECTION:-12
SPECIFICATION FOR
LIFT IRRIGATION SCHEME & PIPE

DISTRIBUTION NETWORK.
2022-23
502
SPECIFICATIONS FOR LIFT IRRIGATION SCHEME & ALLIED WORKS
12.1 SPECIFICATION FOR EXCAVATION FOR SOFT

STRATA(SOIL,HARD MURUM,SOFT ROCK)(Item No. LIPDN 1,2,3)
12.1.1 Description of item

Excavation in soft strata ( Soil, Hard murum, soft rock) including boulders upto 0.6m
diameter (0.113 m) for canal, seating of embankment, filter drains / catch water drains
etc., and placing the excavation stuff neatly in dump area or for formation of service
road / embankment including cost of all materials, machinery , labour, dressing bed
and sides to required level and profile etc. complete with lead upto 1km and all lifts as
directed.
PREPARING AND TESTING OF FOUNDATION

Scaling and trimming of foundations:
operations for the removal of all pieces loosened during excavation or partly
separated from main rock mass by seams or cracks shall be carried out up to the
satisfaction of the Engineer-in-charge.
Testing for soundness:

CLEAN UP
debris and construction materials and contractor's tools, equipments and other
property before the work is finally accepted at his own cost.
THE ITEM OF EXCAVATION WILL INCLUDE

The rate for the item will include as follows:-
a) Soft Strata:-
1) Furnishing all tools and plants, labour and material required for the work
throughout execution.
2) Providing quality assurance.
3) Line out of works, profiles etc. according to sanctioned plan or as directed by
Engineer-in-charge including setting up bench marks and other references.
4) Excavation to the designed section in dry or wet condition and removal of all
materials of whatever nature etc. including materials like explosives, removal
of blows and slips and use of tools, plants and equipments necessary for
satisfactory completion of the item and preparing bed for foundation.
5) Bailing and pumping out water when separate provision does not exists for it in
the contract.
6) Providing and subsequently removing shoring and strutting
7) Sorting out of useful excavated materials, conveying them clear beyond the
503
work area and stacking them neatly, depositing for use in embankment in
proper zone and disposal of surplus material, preparing and testing foundation
etc. with all lead & lift as directed by the Engineer-in-charge.
8) Necessary protection to ensure safety and protection against risk or accident.
9) Supply of facilities for inspection and measurements at any time to the
concerned Government / Corporation.
10) Compensation for injury to life and damage to property if any, caused by
contractor’s operations connected with this work.
b) Hard Strata by blasting / controlled blasting :-
In addition to the points mentioned above which are applicable for excavation in soft
strata, the rate for this item shall include.
1) Drilling and blasting with delay detonators or wedging and breaking for any removal.
2) Loading the tipper and unloading the muck.
3) Marching away for next blasting and re-location after blasting.
4) Labour and staff required.
c) All applicable taxes, royalty and licensing fees etc.
The item of excavation shall include furnishing all tools, plants, labour and
material required, providing quality assurance, providing any road or ramp required
for transportation of excavated material and their maintenance if any, line out of the
profile of excavation, setting out benchmark. Excavation in all types of strata met
with (in dry or wet condition) and to the designed section including controlled
blasting wherever required using delay detonators, providing and subsequently
removing shoring and strutting or cutting slopes etc., bailing out or pumping out
water when separate provision does not exist for it in the contract, sorting of the
excavated material, conveying and staking in stock piles clear beyond the work area
for its use in embankment with all lead and lift, disposal of surplus material in a
manner as directed by the Engineer-in- charge and preparing and testing of
foundation. Maintaining the excavation trenches, vertically preparing the
foundations as shown on the drawing and as directed by the Engineer-in-charge,
drainage and all operations covered within the intent and purpose of this item of
work.
Also the area of open excavation shall, where in the opinion of the Engineer-in-
charge, clearing is necessary be cleared of all trees, bush, rubbish and other
objectionable matter, and the material removed shall be burnt or other-wise disposed
off as directed by the Engineer-in-charge. The scope of work shall also include
deployment of experienced engineers and necessary protection in view of safety,
supply of facility for inspection and taking measurements at any time, compensation
for injury to life and damage to property if any caused by the contractor's operation
etc. The cost of all these items shall be deemed to have been included in the unit rates
of items contracted under excavation, at his own cost etc. all complete..
WORKING UNDER WET CONDITONS:

504
Seepage water from springs or rainwater shall be suitably collected Where, however,
shall be pumped out.
QUALITY ASSURANCE
Quality Assurance is providing the confidence that an entity will fulfill the quality
requirements adequately by the ways of systematic quality planning and
implementation of quality assurance measures. The purpose of quality assurance is to
foresee bottlenecks and prevent them, identify and correct swiftly and suitably any
problems that might occur, and to uncover and eliminate the root cause of the same.
Contractor shall deploy quality assurance system on the work. It comprises the
deployment of experienced engineers in the field of works to be executed under the
agreement, the trained supporting staff for testing the construction material, test
during process & that on completed item as per requirement of Indian Standards for
the item.
equipments for field testing duly calibrated periodically.
Contractor shall carryout periodical tests on material, process & finished end
product. The test report shall be analysed as per prevailing relevant standards.
The monthly Quality Assurance report shall be prepared & submitted to Engineer in
Charge along with the information of work executed, material consumed & man,
machinery engaged for the work.
12.1.3 Material specification
All machines necessary for excavation ie poclains ,trucks, tippers ,dozers etc. and
materials such as pegs, bamboos, strings, templates & survey equipments for
marking out slopes and labour required for line out shall be provided by the
contractor at his own cost and shall be responsible for their maintenance during the
whole construction period.
12.1.4 Sequence of execution
12.1.4.1 Line out
The contractor shall establish at suitable points to the satisfaction of the Engineer-in-
charge permanent reference marks on the centre lines, as may be necessary and
directed. The permanent reference marks shall be inscribed on bronze pegs, set in
substantial concrete blocks where they will be free from any likely-hood of
disturbance. Suitable permanent bench marks shall be established. As the work
progresses, centre line marks shall be made on pegs, inserted at convenient interval to
the satisfaction of the Engineer-in-charge, for checking alignment, grades, levels etc.
and also the dimensions of the minimum excavation lines. The contractor shall, at all
times, remain responsible for the sufficiency and accuracy of all such bench marks
and reference points.
The center line of excavation shall be clearly marked by pegs or lime powder at 30 m.
interval or at change in direction or at shorter intervals on curves, in the beginning as
505
directed by the Engineer-in-charge. The final line out shall be done by fixing
reference stone / concrete pedestal at suitable distances on either side of the center
line beyond the edge of dam, barrage, canal, canal structure and other structure or
any construction edges so that they are not disturbed during the construction period.
The position of these stones shall be marked on the foundation plan and drawings.
No change in the sanctioned plans and designs is permissible without the written
permission of Engineer-in charge.
The contractor shall layout and constructs one or more temporary or permanent bench
marks in some central place before start of the work, from which all important levels
for excavations shall be set. These shall be laid out with the prior approval of
Engineer-in-charge. No base line or benchmark or reference line shall be used
without prior approval of the Engineer-in-charge. The reference points and pillars
already established by the department in the work area shall be fully protected and
maintained by the contractor. He shall repair and rebuild the same in case of any
damage.
permanent bench marks and for taking measurements of the work at his own cost.
The permanent bench marks shall consist of concrete / masonry pillar constructed
with iron plate connected to anchor rod and fixed in the pillar at the centre (with top
of pillar & plate flush) neatly plastered and leveled as per the directions of the
Engineer-in-charge. These permanent bench marks shall be properly established to
ensure no settlements. Bench marks shall be well connected with grid system or any
other bench mark approved by the Engineer-in-charge. The bench mark shall be
checked from adjoining bench mark established or any other bench mark as will be
directed by the Engineer-in-charge at the start of every season. The bench marks shall
be checked at the start of each season.
After the line out is given, the original ground levels shall be taken in the presence of
Engineer-in-charge or his authorized representative before start of the excavation. All
levels shall be referred to an established bench mark not subjected to subsidence or
interference. The contractor shall have to sign the field books and plan showing the
working levels, longitudinal sections and cross sections of the portions of the
alignment that he has to tackle. The contractor has to submit signed field book and
plans showing working levels. If the contractor fails to submit them within three
days, the levels and sections recorded by the Engineer-in-charge will be final and
binding on the contractor and it will be treated that the site is handed over to the
contractor by the department, for all purpose mentioned in the contract.
ACCURACY OF ALIGNMENTS, GRADES, LEVELS ETC:

A few bench marks are fixed reference points, with the value of the levels and the co-
ordinates are fixed by the Government in the work areas. Plans showing the positions,
co-ordinates and level of the salient points will be supplied to the contractor on
demand. The contractor will fix his permanent points bench marks in relation to these.
He shall take all precautions to see that the points fixed by the Government are not
disturbed by his work and shall make good the damage, if any, at his own cost.
The contractor shall excavate true to alignment grade and level and shall check these
506
at frequent intervals as the work progresses. The contractor shall, provide, free of
cost, all facilities like labour, instrument etc. and all co-operation to the Engineer-in-
charge to check the alignment, grades, levels etc. whenever and every time they are
asked for. Such checking by the Engineer-in-charge shall not absolve the contractor
from his responsibility of maintaining the accuracy of the work. Any discrepancy or
error detected during the course of excavation or at the end of the work shall be set
right by the contractor at his own cost in a manner, satisfactory to the Engineer-in-
charge
All the excavated material from the soft strata shall be carefully sorted out and used
in the respective zones in embankment for dam, barrage, canal, canal structures and
any other structure as per it's suitability and as directed by Engineer-in-charge. When
material from excavation is not utilised directly in respective zones, it shall be
stacked separately and neatly in a manner such that it shall be used in a particular
zone only according to its suitability. No intermixing of material of various zones is
allowed while utilising it in embankment. The excavated material which is not
suitable for use in embankment shall be immediately removed and deposited at such a
place and in such a manner as directed by the Engineer-in-charge.
12.1.4.2 Excavation
Work shall be executed as shown in the drawings and as directed by the Engineer-in-
charge. Edges shall be neatly aligned symmetrically to the center line. They shall be
done absolutely straight in straight reaches and smoothly curved on bends.
12.1.4.3 Classfication
The classification of strata shall be as under.
12.1.4.3.1 Soft strata:This shall include:
a) All excavation done in strata such as soil, silt, gravel, soft murum, stiff clay,
kankar and other similar material.
b) Hard murum:
This shall include all kinds of disintegrated rock or shale, indurated clay which can be
removed by means ofpick or shovel.
c) Hard murum and boulder :
This shall include all kinds of disintegrated rock or shale or indurated sand or
conglomerate interspersed with boulders which do not need blasting and can be
removed with pick bar and shovel.
d) Soft rock :
This shall include all excavation in rock done without resorting to blasting and
chiseling and can be removed with a pick bar and shovel or excavator but which shall
not come under the category of Hard murum and boulders.
507
The boulders mentioned in above strata shall have a size measuring up to 0.5 m in
any dimension and up to 1 m in any other two dimensions.
At the change of strata, the contractor shall inform the department in writing
before preceding the work of excavation in hard strata. The Engineer-in-charge
shall take the levels of finished excavation in soft strata. The decision of the Engineer-
in-charge shall be final and binding on the contractor.
Disposal of surplus material :

The excavated material which is not useful shall be stacked in spoil banks with neatly
made stable slopes as directed and properly trimmed, so as to present a neat appearance
or they may be deposited in other approved location.
area and location of spoil banks shall be got approved from the Engineer- in-charge.
In case of temporary stacking of excavated material before use in embankment work,
the same shall be stacked temporarily and arrangements for it shall be done by the
Care shall be taken that no natural drains get obstructed due to spoil banks or there
shall be diversion of natural drainage causing damages of other properties due to spoil
banks.
12.1.5 MODE OF MEASURMENTS
The item will be measured on volume basis.

All linear measurements shall be either horizontal or vertical for arriving at the
quantity. The measurement for the length and the width shall be recorded correct
up to 10 mm, limited, to those shown in the drawings or as directed by the
Engineer and area calculated up to two decimal places.
The measurements shall be based on areas of cross-sections taken normal to the
axis of the structure or its part of the original ground surface and the surface of the
finally completed excavation within the pay lines, taken at every 10 meters along
the axis of structure or its part.
Levels along the cross sections shall be taken at every 15 meters as per necessity
of work. Where there is abrupt change in depth, additional cross sections may be
taken at the discretion of the Engineer-in-charge.
Quantities shall be computed by plotting the actual excavated levels and the
original ground or rock level and calculating the area between the original and the
excavated line from the cross sectional area by Prismoidal formula.
The measurements of excavation shall be the measurements of cut as worked out
from the areas of cross sections of original ground and the finally excavated line
i.e. within the payable excavation lines.
Stack measurements- As a rule, measurement of the excavated material on stacks
shall not be permitted. However, in case of excavation in bouldery strata when it
is not possible to get a record of the excavated material in cross section,
measurement of the excavated material on stacks may be permitted by the
Engineer-in-charge in writing.
In such a case, the stacks shall be on level ground, rectangular in shape and shall
not be more than three meter in height.
The mode of measurement for excavation shall be cubic meter only vertical
508
excavation will be paid.
Excavation for rising main trench shall be carried out vertically with the use at
shoring and strutting whenever required no slopes measurement shall be consider
for payment
.12.1.5.1 MODE OF PAYMENT

Only vertical excavation will be paid , No payment shall be made for any silt,
debris, etc. that might accumulate in excavation pits during monsoons or
summers, showers or otherwise on any account and the removal there of shall be
deemed to have been included in the contract rates for the main items.
509
12.2 SPECIFICATION FOR EXCAVATION IN HARD ROCK (Item No. LIPDN
4)
12.2.1 Description of work
Excavation for deep trenches for laying rising main in Hard Rock of any toughness
by blasting to correct line and level and to specified width including trimming and
levelling the bed as directed, removing the excavated material and sorting, stacking
the same upto a distance of 15 metres and all lifts as directed, preparing the bed for
foundation and keep the trench undisturbed till pipe laying & fixing necessary
specials etc complete as per detailed specifications.
PREPARING AND TESTING OF FOUNDATION

Scaling and trimming of foundations:
operations for the removal of all pieces loosened during excavation or partly separated
from main rock mass by seams or cracks shall be carried out up to the satisfaction of
Testing for soundness:

Cleanup
debris and construction materials and contractor's tools, equipments and other
property before the work is finally accepted at his own cost..
The item of excavation shall include furnishing all tools, plants, labour and material
required, providing quality assurance, providing any road or ramp required for
transportation of excavated material and their maintenance if any, line out of the
profile of excavation, setting out benchmark
Hard rock include all types of rock occurring in masses in all types of geological
formations which could best be removed by blasting or by splitting by mechanical or
chemical means where blasting is not permissible. It shall also include rock which
owing to the proximity of buildings, structures, electric line, and public roads or for
any other reasons has to be cut by means as directed by the Engineer-in-charge. It
shall also include boulders either embedded in mass or isolated ones, measuring over
0.50 m. in any one direction and over 1 m in any other two directions which require
blasting or wedging and breaking for any removal. The hardness of strata of material
to be excavated, presence of different types of geological constituents requiring
increased drilling efforts, consumption of explosives, labour and use of machinery
etc. shall not be considered as reason for claim or increase in contract rates. In case of
disputes over the classification of strata met with during execution, the decision of the
Engineer-in-charge shall be final and shall remain binding on the contractor.
510
12.2.1 MATERIAL SPECIFICATION
All machines necessary for excavation ie poclains ,trucks, tippers ,dozers etc. and
materials such as pegs, bamboos, strings, templates & survey equipments for marking
out slopes and labour required for line out shall be provided by the contractor at his
own cost and shall be responsible for their maintenance during the whole construction
period.
12.2.3.Sequence of execution
12.2.3.1 Excavation in rock
Excavation in rock shall be such that all sharp points of rock be chipped off Blasting
in a manner which is likely to produce overcuts which in the opinion of Engineer-in-
charge is excessive, shall not be permitted beyond pay line and no payment shall be
made for such excess excavation. Special care shall be taken to prevent overcuts or
loosening of materials on bottom and side slopes. The material excavated in a chain
of 30meters shall be conveyed & stacked as directed by Engineer-in-charge.
The excavation shall be carried out according to the design with accurately graded
bed fall and side slopes as shown in the drawings and as directed by the Engineer-in-
charge. The cross section adopted in cutting is likely to change in side slopes
according to the depth and of different strata during actual excavation.
No claims for any variations in quantity of excavation resulting from deviation from
the instruction of the Engineer-in-Charge other than without the written instructions
of the Engineer-in-Charge would be accepted.
12.2.3.2 Blasting
Observing rules regarding blasting:

Where hard rock is met with and blasting operations are considered necessary, the
contractor shall obtain the approval of the Engineer-in-charge in writing for
resorting to blasting operation.
The contractor shall obtain license from the competent authority for undertaking
blasting work as well as for obtaining and storing explosives as per the Explosive
Act 1884, Explosive Rules 2008,The Explosive (Amendment) Rules,2019 and as
amended from time to time.
In conducting blasting operations, proper precautions shall be taken for the protection
of persons, work and property. Explosive act 1884 and the Explosive rules 2008 and
as amended from time to time relating to the design and location of the magazine,
transport, storage, handling, use and disposal of explosives and other measures for the
prevention of accident shall strictly be observed. Warning signs shall be prominently
displayed on the magazines, and warning signals given for each blast.
At all stages of excavation, precautions shall be taken to preserve the rock below and
beyond the lines of required excavation in the soundest possible condition. The quantity
and strength of the explosives used in the foundation excavation rock in various
locations shall be such as will neither open the seams nor damage nor crack the rock
511
outside the limits of excavation.
As the excavation approaches its final lines, the depth of the holes and the strength
and amount of explosives should be progressively and suitably reduced up to within
300 mm to 600 mm of the specified foundation level. Further excavation, up to the
specified foundation level shall be carried out by barring, wedging and chiseling only.
All excavation beyond the minimum excavation lines in the surfaces which have to be
covered by masonry or concrete shall be filled back with the concrete or masonry of the
same quality as that of structural concrete/masonry or as may be directed. No payment
will be made of such final lines and levels.
Contract rates for excavation in rock in the foundation shall include the cost of all
excavation as specified herein up to final and levels.
In case a fault or a wide seam is met with in the foundation, it shall be dealt with as
directed by the Engineer- in-charge. If grouted, it shall be paid for at unit rates there
for. If it cannot be dealt with by grouting, it shall be excavated and back-filled with
concrete or masonry as directed by the Engineer-in-charge and these items shall be
paid for at the unit rates there for in the item of work concerned, except where
otherwise provided.
WORKING UNDER WET CONDITONS:

Seepage water from springs or rainwater shall be suitably collected Where, however,
shall be pumped out.
DISPOSAL OF EXCAVATED MATERIAL:

Suitable material out of the excavation, if approved or directed by the Engineer-in-
charge, shall be used in temporary works as for making platforms, for the stock piles
etc. The balance of the spoils, except that required for the back filling, shall be
removed, deposited and spread on the dump areas as shown in the drawings or as
directed by Engineer-in-charge in a neat and orderly manner . No materials shall be
dumped where it will spoil the aesthetics of the site or interfere with accessibility of
complete structures, nor shall any material be dumped where they may be carried by
flood waters and obstruct the natural course of the river.
Dump areas shall be levelled and trimmed to reasonably regular lines, all work shall
be done with reasonable neatness. Excavated materials shall not be carelessly thrown
over the work area but should be deposited directly in permanent positions, so far as
consistent with proper excavation of the work. The useful materials taken out as stated
above, may be used in masonry or concrete as the case may be, at contractor’s cost.
Storing and transport:

Explosives shall be stored in clean, dry, well ventilated magazines to be built for the
purpose by the contractor at his own cost. Fuses and detonators shall be stored in
separate magazines. Detonators and explosives shall be transported separately to the
blasting site.
Explosives shall be stored in a safe place at sufficient distance from the work and
under the special care of watchman so that in case of accidents, no damage occur to
the other part of the work. No objection certificate from the District Magistrate or
512
Inspector of Explosives shall be obtained as required by the Contractor. The
contractor shall purchase the explosives, fuses, detonators etc. only from a licensed
dealer. Before blasting activity is initiated by the contractor, the approval from
Engineer-in-Charge is necessary. The contractor shall be responsible for the safe
transportation, storage and custody as per the explosive rule and proper accounting of
the explosive materials.
The Engineer-in-charge or his authorized representative has the right to check

the contractor’s store and account of explosives. The contractor shall provide
necessary facilities for this.
The contractor shall remain totally responsible for any damage arising out of
accident for workman, public or property due to storage, transportation and use of
explosive during blasting operation.
Restrictions of blasting:
a) Blasting which may disturb or endanger the stability, safety or the quality of
the foundation shall not be permitted.
b) Blasting within 30 meter of masonry or concrete work in progress or of a
permanent structure is not permitted except special permission is taken from
the Engineer-in-Charge.
c) Progressive blasting shall be limited to two third of the total remaining depth of
excavation.
d) No large scale blasting operations shall be resorted to when the foundation
excavation reaches the last half meter. Only small charges may be allowed so
as not to disturb the foundation. However the excess excavation will have to
be make good by M-20 grade concrete at contractor's risk and cost.
Preparation of blasting :
Explosives shall be kept dry and away from the direct rays of the sun, naked lights,
steam pipes or heated metal etc. Only the quantity of explosives required for a
particular amount of firing to be done shall be brought to the site of work. All surplus
explosives left after filling the holes shall be removed at least 600 m. away from the
firing point.
A wooden stemming rod shall be used to push the cartridge into the shot-hole. Metal
rod or rammer shall not be permitted on the site of work. The charge shall be pressed
firmly into the place and not rammed or pounded.
The explosives shall be fired by means of an electric detonator placed inside a cartridge
and connected to the firing cable.
Due precautions shall be taken to keep the firing circuit insulated from the ground,
bare wires, rails, pipes or any other path of stray currents and to keep the lead wires
short circuited until ready to fire.
Drilling rock for blasting:

The holes for charging explosives shall be drilled with pneumatic drills, the drilling
pattern being so planned that rock pieces after blasting shall be suitable for handling
without any need for secondary blasting. The rock pieces so blasted shall be neatly
stacked at allotted places. Even after taking such precautions, if secondary blasting is
required, it shall be done at the cost of contractor.
513
Blasting operations:
Before any blasting is carried out, it shall be ensured that all workmen, vehicles and
equipments on the site are cleared from an area of 300 meters radius from the firing
point at least 15 minutes before the firing time by sounding a warning siren. The
blasting influence area shall be encircled by red flags.
All operations shall be carried out by the competent and experienced licensed
supervisors. The firing shall be conducted by a supervisor and the number of shots
fired at one time shall not exceed the permissible limits. In case of misfires, the
unexploded charges shall be carefully located after half an hour and shall be exploded
by drilling a fresh hole along side or the misfired hole (but not nearer than 600 mm
from it) and by exploding a new charge. The workmen shall not return to the site of
firing until at least half an hour after firing.
12.2.4 Controlled blasting
Controlled blasting shall be got approved from the Chief Engineer prior to
start with any operation regarding it. Controlled Blasting with delay detonators
achieves good fragmentation with controlled throw, enabling easy mechanical
handling and providing control on ground vibration, noise and moving off rock
chips / pieces.
Short delay series detonators are designed for use in opencast and underground mines,
for driving tunnels, shaft, sinking and in quarries where multi-shot rounds are
required.
Long delay series detonators are designed for use in underground mining for driving
shafts and tunnels. When blasting is conducted in the neighbourhood of roads,
structures, buildings or at any place which requires controlled blasting, only shallow
shot holes shall be drilled. The holes shall be filled with a light charge on explosive
and the blast controlled by placing steel plates loaded with gunny bags filled with
sand or earth over the hole and covering them with wire net fixed to the ground or
any other suitable method so as to ensure that the blasted material do not scatter. In
such cases, short delay detonators shall be used for blasting purpose.
The holes for blasting shall be drilled for a depth of only 40 cm thus increasing the
number of holes and correspondingly decreasing the charge required for each holes.
The holes as far as possible shall be slant. All the holes after charging shall be
covered by grill of steel rods which shall be suitably loaded by gunny bags filled with
sand or murum.
The steel grill shall be so lowered over the holes as not to cause any damages to the
fuse wire or charges and care shall be taken to see that the fuse wires remain free. The
loading shall be sufficient to prevent the overthrow of rock after blasting. In addition
to the above loading, the steel grill shall be securely anchored to the adjoining rock by
chain clamps. The steel grill shall extend at least 3 meters beyond the area to be
blasted.
Contractor shall strictly adhere to the provisions of the prevailing explosive rules
laws, and local laws thereof etc. complete.
514
12.2.4.1 Sorting of materials
Excavated material shall be sorted out as under.
12.2.4.2 Hard Strata
Rubble and boulders from hard strata shall be sorted out and stacked in separate areas
as directed by the Engineer-in-charge. Stock Piles shall be of regular shapes allowing
for easy measurement. No stock piles shall measure more than 200 Sqm in plan and
more than 1.5 m. in height unless specifically permitted by the Engineer-in-charge in
writing.
12.2.4.3 Conveyance of Material
All the excavated material from excavation shall be selected properly by removing
bushes, roots, grass, other objectionable matter etc. and shall be sorted out into
different types of materials according to its suitability for use in different zones of
embankment as directed by Engineer-in-charge. The same shall be loaded in the
vehicles proceeding directly to the place of use except when such material is required
to be stock piled.
12.2.4.4 Stacking and disposal of material
The excavated material shall be stacked within the area approved by the Engineer-in-
charge. Disposal of all material from excavation shall be as per approved disposal
plan or instructions of Engineer-in-charge, regarding the location and deposition of
the stock piles, spoil banks or embankment. Before any excavation is started, the
deposition of soil shall be carefully planned so as not to obstruct normal traffic and
traffic lines.
The material shall be dumped sufficiently clear off the edges of excavation so as not
to endanger stability of the slopes of the excavation and also to permit ample space
for lorry paths, installation and lifting of pumping devices, stacking construction
materials etc. Excavated stuff shall not be dumped near the outlet location. If the
excavated material is deposited in unauthorized land, such work shall not be
measured for payment unless suitable action as directed by the Engineer-in-charge is
taken by the contractor. In addition to non-payment of such work, suitable amount as
directed by the Engineer-in-charge shall be recovered from the contractor as
deposited towards any extra cost which Govt./Corporation may have to bear on
account of the contractor’s unauthorized action.
Stacking and utilizing useful material:

Useful material available from excavation which cannot be used directly shall be
stacked in separate area and with reference to the type of material. Stock piles shall
be as regular in shape as possible as directed by Engineer-in-charge allowing for
easy measurement. The material once stacked shall be utilised as and where
required and as directed by the Engineer-in-charge.
Disposal of surplus material:
The excavated material which is not useful shall be stacked in spoil banks with neatly
made stable slopes as directed and properly trimmed, so as to present a neat appearance
515
or they may be deposited in other approved location.
area and location of spoil banks shall be got approved from the Engineer- in-charge.
In case of temporary stacking of excavated material before use in embankment work,
the same shall be stacked temporarily and arrangements for it shall be done by the
Care shall be taken that no natural drains get obstructed due to spoil banks or there
shall be diversion of natural drainage causing damages of other properties due to spoil
banks.
12.2.4.5 Silting of excavation
Silting due to floods:

Government/Corporation not responsible:
If excavated pits get silted due to intervening floods, slips or any other cause till
completion of the work, the contractor shall excavate and restore the excavated pits
and section to the required shape and dimensions without any extra cost. Contractor
shall so plan that no flood shall damage the underground excavation or shall get silted.
The item will be measured on volume basis.

All linear measurements shall be either horizontal or vertical for arriving at the
quantity. The measurement for the length and the width shall be recorded correct
up to 10 mm, limited, to those shown in the drawings or as directed by the
Engineer and area calculated up to two decimal places.
The measurements shall be based on areas of cross-sections taken normal to the
axis of the structure or its part of the original ground surface and the surface of the
finally completed excavation within the pay lines, taken at every 10 meters along
the axis of structure or its part.
Levels along the cross sections shall be taken at every 15 meters as per necessity
of work. Where there is abrupt change in depth, additional cross sections may be
taken at the discretion of the Engineer-in-charge.
Quantities shall be computed by plotting the actual excavated levels and the
original ground or rock level and calculating the area between the original and the
excavated line from the cross sectional area by Prismoidal formula.
The measurements of excavation shall be the measurements of cut as worked out
from the areas of cross sections of original ground and the finally excavated line
i.e. within the payable excavation lines.
Stack measurements- As a rule, measurement of the excavated material on stacks
shall not be permitted. However, in case of excavation in bouldery strata when it
is not possible to get a record of the excavated material in cross section,
measurement of the excavated material on stacks may be permitted by the
Engineer-in-charge in writing.
In such a case, the stacks shall be on level ground, rectangular in shape and shall
not be more than three meter in height.
The mode of measurement for excavation shall be cubic meter only vertical
excavation will be paid.
PAY LINE
516
Excavation for rising main trench shall be carried out vertically with the use at
shoring and strutting whenever required no slopes measurement shall be consider
for payment.
12.2.5.1 MODE OF PAYMENT

Only vertical excavation will be paid No payment shall be made for any silt,
debris, etc. that might accumulate in excavation pits during monsoons or
summers, showers or otherwise on any account and the removal there of shall be
deemed to have been included in the contract rates for the main items.
517
12.3 SPECIFICATION FOR PREPARATION OF BEDDING (Item No. LIPDN
5,6 & 7 )
Providing and laying bedding in trenches with murum or sand of approved quality
in layers not exceeding 150 mm to 200 mm, each layer shall be compacted by
watering and ramming etc complete as directed.
The underground pipes are generally laid on prepared bedding. The bedding may be
of murum bedding from available or from borrow area , sand bedding.
Sometimes rubble soling is recommended below murum or sand bedding. In no case
pipes shall be directly laid on rock
The specification contained in the Standard Specification Volume-II published by

Public Works and Housing Department, Govt. of Maharashtra, Chapter Bd.A-10,
Page 263 shall apply.
Sand :-Screened sand having size not larger than 5 mm. shall be used. Sand should be
clean. The silt percentage shall not exceed 3.5% by dry volume or 5% by wet volume.
If the silt percentage is more sand shall be washed before using. The sand bedding of
specified thickness shall be laid to true formation level. The sand layer is fully
saturated and then compacted with hand rammer. The reduction in thickness due to
saturation or due to ramming is restored by adding sand.
12.3.4.1 Murum bedding.
After finishing of trenches to the correct depth and required width, the approved
murum /sand shall be laid in layers of 15 cms. Each layer shall be watered and
compacted with heavy rammers as directed before upper layer is laid, till the
required level is reached so as to form a thoroughly compacted base.
i) Cleaning the trenches.
ii) Making the trenches dry.
iii) Making available the murum with all leads and lifts either from excavated stuff or
from borrow,
iv) Laying the murum in layers.
v) Watering and compaction to 90% proctor density.
12.3.4.2 Rubble soling and sand bedding
518
When the soling is specified below murum or sand bedding, it shall be laid with
good quality stone.
The stone shall be well packed the measurements shall be on cum basis. No
deduction shall be made for voids. The rate includes cost of rubble, transportation and
laying.
The sand bedding of specified thickness shall be laid to true formation level. The
sand layer is fully saturated and then compacted with hand rammer. The reduction in
thickness due to saturation or due to ramming is restored by adding sand.
12.3.5 MODE OF MEASURMENT.

The measurement of sand bedding, rubble bedding shall be on cum basis.

The payment shall be made after checking the alignment levels
519
12.4 SPECIFICATION FOR BACKFILLING ( Item No LIPDN 8 )
Backfilling the trenches in layers not exceeding 300 mm, each layer shall be
consolidated by watering and ramming without disturbing the pipe line with
excavated stuff, including breaking of clods of soil etc complete as directed.
The back filling shall be done properly after alingmemt & laying of rising main.The
backfilling on the two sides of the pipeline should be carried out simultaneously.It
shall be done in layers so that the alignment of pipe shall not disturbed. The material
used for back filling mostly from available stuff of excavation. The balance of the
spoils, except that required for the back filling, shall be removed, deposited and
spread on the dump areas as shown in the drawings or as directed by Engineer-in-
charge in a neat and orderly manner . No materials shall be dumped where it will
spoil the aesthetics of the site or interfere with accessibility of complete structures,
nor shall any material be dumped where they may be carried by flood waters and
obstruct the natural course of the river. Dump areas shall be levelled and trimmed to
reasonably regular lines, all work shall be done with reasonable neatness. Excavated
materials shall not be carelessly thrown over the work area but should be deposited
directly in permanent positions, so far as consistent with proper excavation of the
work. The useful materials taken out as stated above, may be used in masonry or
concrete as the case may be, at contractor’s cost.
The material used for back filling mostly from available stuff of excavation and shall
be sorted before back filling . No hard rock material shall be used for backfilling.
The back filling of pipe line trench shall be carried only after completion of hydraulic
test & proper permission shall have to obtain by contracter from Engineer
incharge.Necessary watering shall be done to have proper compaction.

The measurement and payment of back filling shall be on cum basis.

The payment of back filling shall be paid considering shrinkage allowance.
520
12.5 SPECIFICATION FOR FABRICATION OF MS PIPE(Item No LIPDN 9)
Providing & Erecting M.S. pipes made out of MS plate conforming to IS

2062:1992 including procurement of plates, gas cutting to required size, rolling, tack
welding, assembling in suitable lengths to form pipes on automatic welding machine.
The welding Shall be ERW/SAW using electrodes having weldmark E7018 (Low
Hydrogen electrodes) and forming 'V' edge on both ends of pipes, Including third
party inspection charges, lowering and laying to correct position on prepared bedding
or on pedestals or chairs, field hydraulic testing at specified test pressure as per IS
5822: 1994 sec 11, field welding to join pipes after laying, Radiographic (5%) and
ultrasonic (10%) testing of welds including all equipments submitting report, expert
personnel required for testing, interpreting and submitting report along with develop
film where applicable, all incidental charges etc complete as per IS - 3589:2001 and as
per specifications (No negative tolerance in thickness is permissible).
12.5.2 Scope of item
The Item includes the procurement of M.S. Plates, fabrication of M.S. Pipes,.
hydraulic testing,ultrasonic and radiological testing etc. Transportation for laying
and rehandling of pipe from guniting plant to location of laying.
12.5.3.1 Supply of plates
Steel plates of specified thickness confirming to IS 2062-2011 (or latest revision)

shall be used for manufacturing, the pipes. The other types of steel required for
ancillary works like rods channels, l-sections etc. shall also confirm to IS. 2062-
2011.
When the contractor is supposed to procure the

plates, he shall submit the manufactures test
certificate as per the IS 2062-2011 (or latest
revision)
In addition to manufactures test certificate, the third party inspection (tests as
stipulated in IS) shall be carried out from one of the following agency.
Engineers India Limited Mumbai

R.I.T.E.S.(Rail India Technical and Economic Services Mumbai.)
S.G.S. India Ltd.
The third party inspection charges shall be borne by the contractor
The pipes with only one longitudinal joint shall be manufactured. The contractor
shall note this while procuring the steel plates. The sizes shall be ordered suitable for
these criteria.
When there is a provision in the Schedule-A of supply of the steel plates

departmentally, then they shall be deemed to be supplied at departmental store, in
521
the sizes specified in the Schedule-A. In such case the contractor shall note the
following points.
a) The steel required for specials & for ancillary works shall be brought by the
contractor at his own cost. It shall confirm to I.S 2062-2011.
b) The contractor shall make his own arrangements at his own cost for
transporting the plates from departmental store to the work shop.
c) Contractor shall be responsible for any damage to the plates during

transportation or during loading-unloading.
d) Contractor shall be held responsible for any damages or loss or thefts, if any
occurring once and after theplates are issued to him.
12.5.3.2 Electrodes
The electrodes (Low Hydrogen Electrodes having weld marks ET018) shall
conform to I.S. 814-2004 [specifications for covered electrodes for metal arc
welding of mild steel].
In order to maintain a good standard in welding, welders shall be tested by the

contractor before they are entrusted with the job. The welders shall be sufficiently
experienced in welding works to execute works of standards specified in I.S.817 -
1966 . The welder will weld two pieces of flat plates cut out of the plates to be used
on this work together to make test pieces of his welding work. These pieces will be
welded with same electrodes and under the severe conditions exactly similar to those
under which he will be require to weld the pipes and in the most difficult physical
position he would be forced to take for such welding of the pipe. Each test piece so
prepared, will be cut by a milling cutter into three test pieces after rejecting some
portions at the end and then tested as under.
(a) One test piece for tensile strength to determine the braking strength. The
minimum breaking strength specified for the parent plate shall be attained by the
weld in this test.
(b) Two bending test pieces with the weld bend in the middle. These test pieces shall
withstand /without damage exactly as the metal in the parent plate parallel bending
with d=3t where 't’ is the thickness of the plate and ’d’ the internal diameter of the
bend.
Tensile strength test and bending test of weld shall be done for one pipe length per 10
pipe length of weld.
The above test shall be done for each welder and wherever there is change in the lot
of welding rods and weld materials. A periodical test as regards their efficiency shall
also be taken at intervals of about 6 months and those found inefficient shall be
removed from the job. Those who pass the test only shall be posted on the job.
A record shall be maintained showing the names of welders and operators who have
worked on each individual joint. Hand welding when required shall preferably be
522
carried out by a pair of welders so that by observing proper sequence distortion can be
avoid A joint trusted to a particular individual or a pair shall be as far as possible,
completed by them in all respects, including sealing run. No helper or other
unauthorized person shall be permitted to do any welding what so ever. In case of
infringement of above the persons shall be punished as directed by the Engineer-in-
Charge.
12.5.4 Sequence of the work
12.5.4.1 Factory
The contractor shall establish a well-equipped fabrication shop with all necessary
mechanical and electrical equipments in sound working order for carrying out the
various operations involved in the work under this contract. The fabrication shop
should be established within 3(three) months from the date of work order. The
fabrication shop so established should be able to produce pipes as per specifications
and at the rate required to complete the work within the specified time limit. The
fabrication shop shall provide for testing facilities like hydraulic testing, radiographic
testing, etc. Failure to establish such a Fabrication shop will be dealt with in terms of
relevant clauses of the Form B-1 of contract.
The factory shall be equipped with the following minimum number of equipments.
(i) Plate bending machine 1 No.
(ii) Automatic welding machine
For inside welding 1 No.
For outside welding 1 No.
(iii) Hydraulic testing machine capable of

testing of length to be fabricated 1 No.
(iv) Adequate gantry or crane of required capacity 1 No.
(v) Channel bending machine suitable for rolling ring 1 No.

girdle 1 No.
(vi) Lathe machine for machining the flange rings 1 No.
(vii) Mobile crane for loading. Adequate unloading of
pipes
(viii) Cold pressing equipment for plates of required
thickness and required curvature 1 No.
Corporation's land is not available for fabrication yard and for labour colony, offices
etc. The contractor has to temporarily hire the land from concerned land owners.
12.5.4.2 Cutting plates to sizes
Before cutting all the edges of the plates shall be cleaned by brushing/grinding on
523
both the sides. Cutting the plate edge preparation and welding will be as shown in the
contract drawings.
The plate shall be cut on all the four sides to the exact dimension and shape.
Tolerance in cutting shall be plus and minus 3 mm. in width and length. The
plates shall be given a bevel at the edges depending upon the welding machine to
be used. The ends of the pipes fabricated shall necessarily have "V" edges, as in
the field hand welding is to be done. For the pipes of 1200 mm and above in dia.
the bevel shall generally be from inside. And for pipes of larger dia. the bevel
shall generally be from outside.
However, the bevel shall be provided from inside or outside in particular cases as
ordered by Engineer-in- Charge.
After the plates are cut, the edges shall be made smooth and even by polishing
with an electrical and pneumatic grinder to remove all inequalities.
Care shall be taken to see that the cut edges of the plates are perfectly straight Jigs
to be used for this purpose shall depend upon the type of cutting machine used.
The plates cut to the required shape shall be checked for correctness before they
are rolled into pipe drums. If any corrections are required, the contractor shall do
the same by re-cutting if necessary.
If any plate is found to be wrapped to have corrugations, the defects shall be
removed by putting the plate into roller-press and no extra payment for this
rectification work shall be made.
If during cutting any plates are found to be laminated, they shall be stacked
separately in the yard. The contractor is not entitled to claim any compensation for
handling and cutting such laminated plates as their percentage on the whole work
will be generally negligible.
Similarly if any badly corroded steel plates are detected at the time of cutting the
same shall be pointed out to the Engineer-in-Charge and if rejected by him the
same shall be stacked separately and dealt with as in the case of laminated plates.
The average diameter of the pipe shall not be more or less than 0.75 % of
specified Internal Dia. The average diameter will be checked by measuring the
circumference at several sections spaced about 1.5 m. from one another However,
the tolerance in the diameter of pipe particularly at the two ends shall not be more
than plus or minus 1 mm.
12.5.4.3 Rolling of plates
The plates will be cold bent only. The pipes shall be truly cylindrical, and straight
in axis.
The ends shall be accurately cut and shaped for field welding. The external
circumference of the pipes particularly at the ends shall not deviate from the
theoretical one by more than + or -1 mm.
The curvature shall be checked by the contractor's foreman during rolling and
rolling shall be repeated till exact curvature is achieved.
The external circumference of pipe pieces which are to be fixed adjacent to
flange adopter with fixed outer diameter shall not deviate from theoretical one by
more than 1 mm.
To obtain this accuracy the pipe shall be rolled several times, if necessary, as pipe
pieces should be truly cylindrical.
The external longitudinal welding of this pipe shall be ground smooth in flush
with surface to the satisfaction of the Engineer-in-Charge for entire length. No
524
extra cost shall be charged by the contractor for this grinding work.
12.5.4.4 Tacking the drums
The rolled drums shall be tacked properly. To achieve this objective clamp spiders,
tightening rings and/or any other approved gadgets shall be used. The contractor shall
provide at his cost suitable gadget to check the correctness shall be as per Para 8 of IS
3589-2001. Each such drum, before being taken to the assembly platform shall be
numbered on the inside with oil paint.
And as there is possibility that the pipe may lose its shape under its own weight, the
cross bracing of M.S. angles shall be welded on both the faces of pipes internally.
Provision for this is made in item rate and hence no separate payment shall be
paid for such bressings.
12.5.4.5 Assembly of drums into pipes
The tacked drums shall be transported to an assembly platform where they shall be
tack welded together toform suitable pipe lengths.
The longitudinal joints shall be staggered as shown on the drawing or as directed.
The assembly shall be truly cylindrical and without any kinks. The faces shall be at
right angles to the axis of the cylinder. Suitable arrangements for testing the
correctness of the faces shall be provided by the contractor at the assembly platform
12.5.4.6 Welding
12.5.4.6.1 Shop welding
The shop welding either from outside or from inside shall be done on automatic
welding machine. The automatic welding machine shall be submerged arc welding
machine of approved make.
Full welding of tack welded pipe drums and welding required for jointing the pipe
drums into pipes of suitable length shall be done, in shop on automatic welding
machine.
12.5.4.6.2 Field welding
The manual welding is allowed on field but it shall comply with the provisions of I.S.
816-1969 (code of practice for metal arc welding). The welding required for fixing
specials and fixtures on pipeline, shall be paid under the item of field welding.
Welded joints (other than for closing lengths) shall be of the butt welded type
Circumferential welded, both internally and externally. All fillet welds shall have a
throat thickness not less than 0.7 times thethickness of the pipe to be welded.
All parts to be welded shall have loose scale, slag, rust, paints and other foreign matter
removed by means of a wire brush and shall be left clean and dry. All scale and slag
525
shall be removed from each weld when it is completed.
12.5.4.6.3 Gouging / Grinding
M.S. Pipes will have to be welded internally and externally V cut is made from
inside/ outside of the pipes and after it internal/external welding (sealing run) is
completed. Before starting the external/internal welding (sealing run) the
internal/external welded material in the joint will have to be cleaned by
grinding/gouging with grinder or with gas flame. Gouging/Grinding shall be done
before starting the external internal welding (sealing run)and the rate of welding shall
include the cost of grinding / gouging.
12.5.4.7 Radiographic testing and ultrasonic testing
i) The contractor shall carry out the radiographic Testing and Ultrasonic Testing in
accordance with thesespecifications mentioned in 12.7., 12.8.
12.5.4.8 Hydraulic test
1. Depending on the requirements of the pipe laying works, pipes will have to be
manufactured in standard lengths. The contractor shall provide machines and
appearances for testing all pipes of lengths standardized by the Engineer-in-Charge
from time to time.
2. The pipe to be tested shall be given a Serial No. which shall be painted on its inside
together with details such as pipe Nos. shell thickness dia. length etc. as directed. It
shall be entered in the register to be maintained by the Contractor.
3. Prior to testing the pipe shall be inspected thoroughly. All the apparent defects in
welding such as jumps porosity etc. shall be repaired by gouging and re-welding.
4. The hydraulic test shall be carried out under cover at the fabrication shop, in the
presence of and to the satisfaction of the Engineer-in-Charge. Under no
circumstances, the hydraulic test shall be carried out in the absence of the Engineer-
in-Charge or his representative.
5. For indicating the pressure inside the pipe an accurate pressure gauge of approved
make duly tested for the correctness of reading shall be mounted on of the closures
which close the pipe ends.
6. The pressures shall be applied gradually by approved means and shall be
maintained for at least two minutes as pr IS 3589-2001 and IS 5822-1994 during
which time the pipes shall be hammered, throughout its length with sharp blows by
means of a 1 Kg. hand hammer.
7. The pipe shall stand the test without showing any signs of weakness, leakage
oozing or sweating. If any leak or sweating is observed in the welded joints the
same shall be repaired by gouging and re- welding after dewatering the pipe. The
repaired pipe shall be re-tested to conform to the specified pressure.
8. If any leak or sweating is observed in the pipe shell the pipe under test shall be
rejected temporarily. The contractor shall stack such rejected pipes separately in his
yard. The Engineer-in-Charge shall inspect the same and after taking cuts if
necessary shall determine the nature of repairs to be carried out thereon and shall
then deckle as to how and where they shall be used. No payment shall be made for
handling or carrying out repairs, but payment for the fabrications and hydraulic
testing of the pipe shall be released after necessary repairs etc. are carried out by the
contractor to the satisfaction of the Engineer-in-charge.
9. No pipes shall be transported out of the factory to the site of work unless they are
hydraulically and radio graphically tested except permitted by the Engineer-in-
526
Charge in writing to do so. Any failure to comply with this may cause the
contractor payment to be withhold.

• Measurment of pipes shall be taken on weight basis. The measurements under this
item shall be on weight in Kilogram basis and weight shall be theoretically
calculated as directed by Engineer-In-Charge.
The weight shall be
calculated as follows,
M = (D – T) X T X
0.0246615 X L
Where,
M = Weight of pipe in kg., D = Nominal outside
diameter of pipe in mm. T = Nominal thickness of
pipe in mm., L= Length of pipe in meter.
The unit rate includes all the activities mentioned below,
a) Supply of steel plate.
b) Transportation up to site.
c) Plate Cutting
d) Plate Bending
e) Preparing Drums
f) Assembling the drums
g) Welding
h) Hydraulic testing
i) Testing the 5 % weld length radio graphically and 10 % ultrasonic testing
of weld length.
j) Stacking in the stock yard at site after welding the cross bracing

The 75 % payment shall be released only when the pipes of specified lengths and
diameters are manufactured as per specifications and after the successful shop
hydraulic test and after testing the weld length radio graphically and after pipes
are brought on site. Afterwards 15 % rate shall be released when successful field
hydraulic testing is done and,
10 % payment shall be released after successful commissioning of Lift Irrigation
Scheme.
For pipe line the defect liability period should be 3 years of working of scheme.
The efforts shall be made by the corporation to arrange for other requirements for
commissioning within stipulated period of contract.
However if scheme cannot be commissioned within contact period, the contractor

shall not claim for withheld amount or any additional amount. In such situation
contract period shall be extended by Maximum 1 year and amount to be released after
commissioning and* after 12 months performance period shall be delayed
accordingly. It shall be assumed that the prospective bidder (who subsequently turned
out to be the successful bidder), while quoting for his offer, was fully aware of this
provision.)
527
12.6 SPECIFICATION FOR LOWERING, LAYING M.S. PIPE &
M.S.SPECIALS (Item No LIPDN 10 )
12.6.1Description of item
Lowering, laying in position to correct line & level including M.S. pipes with /
without any outcoating on prepared bedding or on pedaetals or chairs or upon
prepared formation including loading, unloading, hoisting, marginal cutting wherever
required, assembling , and transportation upto 500 m etc. completed as specified with
all leads & lifts etc. complete including tack welding, field hydraulic testing at
specified pressure and as per procedure mentioned in section 11 of IS 5822: 1994.
(item to be used only in situations where pipes are already procured ).
The pipeline to be laid under the contract is below ground or above ground, or
pipeline to be laid underground it is laid on murum / sand bedding. For pipeline to be
laid above ground the pipeline shall be supported on concrete chair.. However,
Engineer-in-charge may make modifications depending on site conditions.
The contractor shall employ the skilled engineer to fix alignment with the dilate and
level.
12.6.2.1 MATERIAL SPECIFICATION
All machines necessary for laying M.S.Pipes, welding, field hydraulic

testing at specified presser along with labor shall be provided by the contractor at is
own cast and shall be responsible for their maintenance during the whole
construction period
Quality Assurance is providing the confidence that an entity will fulfill the
quality requirements adequately by the ways of systematic quality planning and
implementation of quality assurance measures. The purpose of quality assurance is to
foresee bottlenecks and prevent them, identify and correct swiftly and suitably any
problems that might occur, and to uncover and eliminate the root cause of the same.
Contractor shall deploy quality assurance system on this work. It comprises the
deployment of experienced engineers in the field of works to be executed under
this agreement, the trained supporting staff for testing the construction material,
test during process & that on completed item as per requirement of Indian
Standards for the item.
equipments for field testing duly calibrated periodically.
Contractor shall carryout periodical tests on material, process & finished end
product. The test report shall be analysed as per prevailing relevant standards.
The monthly Quality Assurance report shall be prepared & submitted to Engineer
in Charge along with the information of work executed, material consumed &
man, machinery engaged for the work.
Laying of underground pipeline.
528
i) The pipe if not gunitted in the shop shall be first gunitted, before lowering into the
trench.
ii) The pipe shall be lowered into the trench with due care so that no guniting is
damaged and pipe is not distorted.
iii) Pipe is laid to correct line and level. The line and level shall be checked with
leveling instrument and thetheodolite.
iv) While assembling care shall be taken to see that longitudinal joints of the two
adjacent pipes are staggered by 60 degrees.
v) The ends of the pipes shall be brought close enough to leave a uniform gap not
exceeding 3 mm. is necessary, marginal cut may be taken to ensure a close fit. There
shall be no lateral displacement between the pipe faces to be joined. If necessary
spiders from inside and tightening. Rings from outside shall be used to bring the two
ends in perfect contact. An alignment it may also be necessary to use jacks for this
purpose. In no case hammering of longitudinal slithering shall be permitted.
vi) If any pipe of odd length required to fill a gap same shall be fabricated and
assembled after coatings.
vii) Tack welding circumferential joining shall then be welded fully for which payment
shall be made separate.
viii) If specials such as bends, tappers etc. shall be laid in the same manner as pipes.
ix) If the empty pipeline is subjected to uplift, it is likely to float and be damages. To
avoid this, a normal practice shall be kept to refill the trench immediately after the
pipe is laid and specials are assembled. The overburden shall be limited to the
specified depth. Anchor blocks at intermediate lengths shall be constructed at the end
of season that is before on set of monsoon. It is advisable to close the two ends of
pipeline by welding plates on its faces and filling lines with water.
x) Design of individual thrust block / anchor blocks shall be made available by the
contractor from the competent authority. The distance between two successive fixity
points shall not be generally exceed 300m. The concrete of these blocks shall be paid
separately.
xi) To facilitate welding and guniting of the circumferential field joint pits shall be
excavated at such locations at the bottom and on the sides. The size of the pit shall
be 600 mm. in width on each side and 600 mm. in depth and 1000 mm. long. This
excavation shall be paid separately under relevant item.
xii) The rubber seals to be used for jointing the pipes should confirm the IS 5382-1985
and should be tested for all the tests enumerated in the above Indian standard.
Laying the pipe above ground.

General sequence shall be as below.
i) Laying of the pipe shall start only after sufficient number of chair pedestals, have
been constructed on site to correct line and level and sufficient stock of specials is
available.Also the line and levels of pedestals shall be checked by the Engineer-in-
charge.
ii) The pipe laying shall start from successive fixity point towards expansion joints.
iii) Depending upon the distance between successive chairs and tresseles and the
length of the pipes fabricated two pieces may welded on site before laying so that after
laying it rests on the next chair and over hands for at least half the length on the pipe.
iv) Normally not more than 1 pipe shall be aligned tacked and kept in position of the
chair / tressels.
v) During assembly pipes shall be additionally supported on adequate wooden
slippers or scaffolding as necessary, kept in between the chairs / tressles.
vi) While assembling the pipes the ends shall be brought to leave a uniform gap not
exceeding 3 mm.
vii) Full welding of circumferential joints shall be done only after the Engineer-in-
charge has checked the correctness of the alignment and level.
529
viii) In this fashion the work of laying and welding of pipe shall continue till the time
comes when the expansion joints is to be fixed.
Fixing of expansion joint and all other activities connected with it are very important
and the contractor shall carry out all above operations under the continuous
supervision and direction of Engineer-in-charge. However, the presence of Engineer-
in-charge or his representative shall not relieve the contractor from his responsibility.

The mode of measurement for lying of pipes shall be on Rmt. basis.
12.6.4.1 Mode of payment.

The 75 % payment shall be released only when the pipes of specified lengths and
diameters are manufactured as per specifications and after the successful shop
hydraulic test and after testing the 10 % weld length radiographically and after
pipes are brought on site. Afterwards 15 % payment shall be released when
successful field hydraulic testing is done and,
10 % payment shall be released after successful commissioning of Lift Irrigation
Scheme.
The successful commissioning of scheme includes passing of design discharge
through pipe line of stipulated diameter.
530
12.7 SPECIFICATION FOR M.S.SPECIALS
(tapers, ‘Y’ connection with crotch plate, ‘Y’and ‘T’branches, manhole covers,
MS bends,short pipe ,cants)(Item No LIPDN 11 to LIPDN 16)
Providing and Erecting tapers, Y connection ,Y and T branches, Manhole covers, MS

bends, short pipes cants made out of MS plate conforming to IS 2062:1992 including
procurement of plates, gas cutting to required size and shape, rolling, tack welding,
full welding on either automatic welding machine or manually and forming 'V' edge
on both ends for welding it to pipe, including fabrication & full welding of stiffeners
as per design requirements, third party inspection charges, lowering & laying to
correct position etc, complete as per IS - 3589 and IS - 5504 as applicable and as per
detailed specifications. Cost of longitudinal welding and " V " edging required for
circumferencial welding required to connect MS special to Rising main /delivery
pipes is inclusive in the rate however circumferencial welding for connecting the
M.S. special to Rising main shall be paid seperately on running meter basis. (No
negative Tolerance in thickness is permissible).
The specials and appurtenances to be fabricated and supplied under this contract are
as follows.
Composite bends
Tapers
Saddle pieces, loose stiffener rings, pressure and non-pressure type black flanges,
ladder, platforms etc..
"Y" branches & "T branches, & bypass assembly
Dished closures such as domes, manhole covers.
Loose flange rings, stress relieving flange rings, plug plates
Expansion joints
Ring girders, stools, M.S. Rollers
Protective covers for B.F. Valves
Miscellaneous specials
not covered
above. Item to
include:-
i) Supply of steel plates, transportation of plate’s upto site.

ii) Cutting to required size & shape.
iii) Rolling the same into drums.
iv) Tacking of drums.
v) Full butt welding or the longitudinal joining on automatic welding machine or
manu
ally.
vi) Forming ‘V’ edge to the both ends of pipe.
vii) In case of pipe places to be fixed near flange adopted, the grinding of
welded joint from outside in flush with outside surface for a length of 200 mm. and
531
truing of.
viii) Stacking the MS specials in the fabrication yard at site etc. complete
including all hoisting, haulageetc.
In case two longitudinal joints are required to be made while fabricating short pipes
as per the instructions of Engineer-in-charge only due to non-availability of plates of
exact size, extra payment for the welding of additional longitudinal joint shall be
made separately under the relevant item (i.e. Gas or electric welding) of Schedule-
B. Extra payment on this account will not be made under any other ite
12.7.3.1 Tapers
Fabricating tapers from the steel plates including cutting the plates, rolling, tack-
welding either on automatic welding machine or manually and forming ‘V’ edge to
both ends of tapers including the longitudinal butt welding to form drums, the cost of
fabrication of stiffener rings and gussets and mounting the same on tapers, tack and
chain welding, stacking the same in fabrication yard but excluding circumferential
butt welding required for assembling drums to form necessary tapers.-
The work shall be carried out as per detailed specifications.
The measurement under this item shall be per tone and weight shall be theoretically
calculated. The weight of stiffener or labyrinth rings or gussets fixed on the taper shall
also be included for payment under this item.
The rate under this item includes-
(i) Cutting to required size and shape
(ii) Rolling into conical drums.
(iii) Tacking the drums.
(iv) Full butt welding of the longitudinal joints and tack welding of gussets,
stiffener or labyrinth rings manually.
(v) Assembling the drums to form full length of taper or part thereof a length suitable
for transport.
(vi) Forming V edges to both the ends of tapers.
(vii) Stacking the tapers so fabricated in the fabrication yard including all hoisting,
haulage etc.
Fabricating specials and fixtures from procured steel materials by the contractor
including finishing etc. complete as per specifications.
The work shall be carried out as per detailed specifications
12.7.3.2 Composite bends
The composite bend shall consist of two or more pieces welded together to give the
required deflection. Fabrication of composite bends from M.S. plates including
cutting the plates, rolling, tack welding drums, assembling to form bend of suitable
532
length welding either on automatic welding machine or manually and forming 'V
edge to both ends of bend excluding the circumferential butt welding required for
assembling cants to form necessary composite bend but including the cost of
longitudinal butt welding of pipe streaks including stacking.
Before cutting the plates, the contractor shall first compute the development of the
shape and shall make templates" wherever necessary. If the templates cannot be
prepared the shape be drawn on the plate and cut betaken.
The work shall be carried out as per detailed specifications.
The measurement under this item shall be per kg of composite bends and shall be
taken along the center line of the same.
The rate under this item includes:
(i) Cutting to required size and shape.
(ii) Rolling the same into drums.
(iii) Tacking the drums.
(iv) Full butt welding of the longitudinal joint on automatic machine or manually.
(v) Assembling the drums to form a composite bend of suitable length.
(vi) Forming V edge to both ends of the bend and
(vii) Stacking the fabricated bends in the fabrication yard etc. complete including all
hoisting, haulage, etc.
However, full welding of circumferential joints manually which will be paid separately
under relevant item.
For calculation of length of welding of these joints for payment the internal
diameter of the regular pipe will be taken as a criterion neglecting the oblique nature
of such joints.
12.7.3.3 Fabrication of one piece cants, short pipes
Fabricating one piece cants, short pipes (shorter than one strake length) from the M.S.
Plates, including cutting the plates to required size, rolling, tack welding either on
automatic welding machine or manually and forming V edge to the both ends of pipes
including stacking the pipes in manufacturing yard etc.
The work shall be carried out as per detailed specification. The rate under this item
includes:
(i) Cutting to required size and shape.
(ii) Rolling the same into drums (i.e. one piece cant or short,(pipe))
(iii) Tacking the drum.
533
(iv) Full butt welding of the longitudinal joint on automatic welding machine or
manually.
(v) Forming edge to the both ends of pipe.
(vi) In case of pipe pieces to be fixed near flange adopter, the grinding of welded
joint from outside in flush with outside surface for a length of 200 mm and
truing of diameter to the satisfaction of Engineer-in- Charge shall be done.
(vii) Stacking the fabricated cant or steel pipes in the fabrication yard etc.
complete including all hoisting, haulage etc. The rate shall be paid per kg.
In case two longitudinal joints are required to be made white fabricating short pipes as
per the instruction of
Engineer-in-Charge only due to non-availability of plates of exact size, extra
payment for the welding of additional longitudinal joint shall be made separately
under the relevant item (i.e. Gas or Electric welding) of Schedule 'B' Extra
payment on this account will not be made under any other item.
(i) Saddle Pieces:
Saddle pieces, of specified diameter shall be fabricated to fit properly on the pipes.
The width of the saddle piece shall be 450 mm. approximately.
(ii) Dished closures such as manholes cover:
For fabrication of dished manhole covers, the contractor shall use special dyes in
hydraulic press to obtain the required shape. The plate shall be cold pressed and no
heating shall be permitted. The rate to include cutting cold pressing and tack welding.
The rate also include drilling holes including grinding wherever necessary, supply of
material at contractor's cost etc. complete as per drawing.
(iii) 'Y’ branches 'T' branches:
The rate to include cutting bending tack welding etc. complete.
(iv) Flat manhole cover:
The rate to include cutting tack welding, the rate also to include drilling holes is
including grinding wherever necessary supply of all material at contractor's cost
complete as per drawing.
(v) Flange Rings of all thickness:
The rate to include all material gas cutting, tack, welding, welding to form a
ring wherever necessary drilling holes including grinding wherever necessary,
including machining the flange rings of all thickness and Stress relieving of flange
rings as specified and directed.
The work shall be carried out as per detailed specifications for
fabrication of pipes and specials. The specials and fixtures shall be
534
fabricated as per the drawings supplied by the Engineer-in-Charge.
Special care to be taken during fabrication of composite bends, tees, and Y

branches. The testing of these specials is not envisaged at the fabrication stage.
They shall be subjected to test when completed pipe line is tested hydraulically. In
view of this, the contractor in his own interest shall fabricate these specials with all
the cares, so that there is no failure of any welded joint during testing of completed
line.
Same as material specification for MS pipe Sr No.12.5.3
12.7.5 Sequence of work
Same as per MS pipe Sr. no 12.5.4
12.7.6 MODE OF MEASURMENT
The measurements under this item shall be on weight in Kilogram basis and weight
shall be theoretically calculated as directed by Engineer-In-Charge.
12.7.6.1 MODE OF PAYMENT:
The weight of stiffeners or labyrinth rings or gussets fixed on tappers shall also be
included for Payment under this item. The rate includes complete welding for complete
manufacturing of the special. The 75% payment shall be released only when M.S
Specials of Specified lengths and diameters are manufactured as per specifications and
brought on site. Afterwards 15 % payment shall be released when successful field
hydraulic testing is done and,
• 10 % payment shall be released after successful commissioning of Lift
Irrigation Scheme.
535
12.8 SPECIFICATION FOR RADIOGRAPHIC TESTING OF WELDING(Item
No LIPDN 17)
Radiographic testing of welded butt joints in Rising main as per Procedure given
in IS 4853:1982 including cost of all materials, equipments & expert personnel
required for testing, developing, interpreting and submitting report along with
developed films, including all incidental charges, transportation to site and local
transportation on site etc. complete.
a) Before commencing fabrication the contractor shall establish a weld identification

scheme. The numbering system shall be used for identification purpose on all shop
drawings, radiographs, NDF test reports and repairs. The notations used for reporting
all weld inspections shall be clearly marked on the work in paint to ensure exact
location of weld defects reported.
(b) Alllongitudinal butt welds and shop circumferential butt welds shall be radio
graphically examined for five percentof the length of welds done in shop or as
directed by Engineer-in-charge at the location directed by the Engineer-in-charge.
(c)All the areas of welds on which repairs have been made shall be examined
100 percent by the method specified for the original weld. This examination shall
be at the contractor's expense.
(d) In case of machine welding if any defect is observed for the entire length of the
film the adjacent location on either side shall be radio graphed at contractor's cost.
The repairs and retests shall be approved by the Engineer-in-Charge This procedure
shall be repeated if necessary till such time as the defects are finally removed to the
satisfaction of Engineer-in-charge.
Such repairs shall not be more than two times at the same locations. If the fault
continues at the spot after two repairs the action to be taken including replacement of
damaged plate and pipe shall be decided by the Engineer-in-Charge but this would
be at contractor's cost.
(e)When weld thus examined shows many unacceptable defects distributed over its
length or when the defects envisage need for rectification of more than 25% of the
weld length, the entire weld length may be rejected and the weld cut out and re-
welded and shall be re-examined by the method specified for the original weld at the
expense of contractor. It should be noted that any radiography carried out
The contractor shall provide at his own expenses all material including radiographic
films of 16" length 3" wide (40 cm length and 76mm wide)and all equipment etc
necessary for radiographic examination and shall perform all radiographic
examination in occurrence with the requirements of this specification and of the
536
Engineer-in-Charge and shall submit all films duly developed to the Engineer-in-
Charge within eight working hours after taking the exposure. The films with then
become the property of the Government.

12.8.5.1 Radiographic Testing
(a) Radiographic shall be performed in accordance with ASME Boiler and Pressure
vessel Section-V Article 2 or equivalent Indian Standard. The image quality indicates
shall be of wire type and the sensitivity shall be at least 1.5 percent or better.T
acceptance standard for radiography shall be as stated in Para 12.8.1 (f) below,
(b) All radiography shall be performed and supervised by the experienced personnel
qualified or trained for the job from the institutes such as Bhabha Research Center or
other reputed Institute of Non-destructive examination.
(c) Prior to making radiography, identification markers shall be placed adjacent

to the weld intended to be radio graphed. The images of such markers shall
clearly appear in the radiographs. It shall be ensured that actual weld and its
radiographs are mutually identifiable up to completion and acceptance of the
work.
(d) At least 30 days prior to commencing radiographic examination the contractor

shall submit details of all radiographic equipment processes and procedures for the
approval of the Engineer-in-Charge. The type and make of the radiographic films
intended to be used shall also be got approved from the Engineer-in-Charge.
(e) Along with each radiographic the contractor shall furnish his interpretation
report in duplicate in the proforma given on at the end of this section. The
Engineer-in-Charge shall be free to make independent interpretation and ask for
the repairing of welds, if necessary.
(f) Sections of welds the radiographs of which show any of the following types
of imperfections shall bejudged unacceptable.
(i) Any type of crack or zone of incomplete fusion or penetration.
(ii) Any elongated slag inclusion or cavities which have length greater than 10 % of T
in the case of length and width 2% of T in plate thickness where T is the thickness of
the plate.
(iii) Any group of slag inclusions in line that have an aggregate length greater
than ‘t’ in a length of 12 ‘t’ except when the distance between the successive
imperfections exceeds 6 L where L is the length of the longest imperfection in
the group.
(iv) Porosity or rounded indications in excess of that specified by the acceptance

standards given in Appendix- IV of ASME Boiler and pressure vessels code Section –
VII Div. 1
537
The measurements shall be on running meter basis as per diameter of pipe.
The payment for radiographic testing shall be made on the basis of actual weld
length tested. Tests on failed and repaired specimens shall not be paid.
538
12.9 SPECIFICATION FOR ULTRASONIC TESTING OF WELDING (Item No.
LIPDN 18)
- Ultrasonic testing of field welded joints as per Procedure laid down in IS 4260:1986
including actual testing, interpreting and submitting test report in detail including cost
of all materials, equipments & expert personnel required for testing, developing,
interpreting and submitting report, including all incidental charges, transportation to
site and local transportation on site etc. complete. .
a) Before commencing fabrication the contractor shall establish a weld identification

scheme. The numbering system shall be used for identification purpose on all shop
drawings, radiographs, NDF test reports and repairs. The notations used for reporting
all weld inspections shall be clearly marked on the work in paint to ensure exact
location of weld defects reported.
(b) Butt joints Field Circumferential welds shall be examined ultrasonicallyfor ten
percent of the length of field circumferential weld or as directed by Engineer-in-
charge at the locations directed by the Engineer-in- charge.
(c) All the areas of welds on which repairs have been made shall be examined
100 percent by the method specified for the original weld. This examination shall
be at the contractor's expense.
(d) In case of machine welding if any defect is observed for the entire length the
adjacent location on either side shall be tested at contractor's cost. The repairs and
retests shall be approved by the Engineer-in-Charge This procedure shall be repeated
if necessary till such time as the defects are finally removed to the satisfaction of
Engineer-in-charge.
Such repairs shall not be more than two times at the same locations. If the fault
continues at the spot after two repairs the action to be taken including replacement of
damaged plate and pipe shall be decided by the Engineer-in-Charge but this would
be at contractor's cost.
(e) When weld thus examined shows many unacceptable defects distributed over its
length or when the defects envisage need for rectification of more than 25% of the
weld length, the entire weld length may be rejected and the weld cut out and re-
welded and shall be re-examined by the method specified for the original weld at the
expense of contractor.
The contractor shall provide at his own expenses all material including ultrasonic
testing machine, all equipment etc necessary for examination and shall perform all
examination in occurrence with the requirements of this specification and of the
539
Engineer-in-Charge and shall submit all reports to the Engineer- in-Charge within
eight working hours after taking the exposure. The report with then become the
property ofthe Government.
12.9.5.1 Ultrasonic Testing
(a) Ultrasonic examination shall be performed in accordance with the Article-5 of

ASME Boiler and pressure vessels code Section-V. The relevant references from
ASTM specifications-154.74 shall also be taken. The ultrasonic examination shall be
performed and supervised by experienced and qualified personnel. If necessary special
type of transudes and/or higher test frequency etc. shall be adopted to improve the
reliability of the examination. If equipment with recording facilities is available in the
Indian market such equipment shall be used for ultrasonic examination. The records
in such case shall be furnished and the same shall be the property of Government.
(b) All conditions which produce a response greater than 20% of the reference level
shall be investigated to the extent that the operator can determine the shape, identity
and location of all such reflectors and evaluate them in terms of the acceptance
standard given in (i) and (ii) below-
(i) Discontinuities shall be unacceptable if the amplitude exceeds the reference level
and discontinuities have length which exceeds (1/3)t where t is the thickness of the
weld being examined.
(ii) Where discontinuities are interpreted to be crack, lack of fusion or incomplete

penetration they shall be unacceptable regardless of discontinuity of signal
amplitude.
12.9.5.2 Additional Examination
(a) The contractor shall make available continuously throughout the Contract
technician and all equipments necessary for Ultrasonic examination of the welds.
The Engineer-in-Charge will direct which welds are to be examined.
(b) Defects which have been detected by Ultrasonic examination shall be repaired as
directed by the Engineer- in-Charge. Any defects which produce an ultrasonic echo
that fails to reveal the nature of the defects shall be radio graphically examined when
so directed by the Engineer-in-Charge. Radiography carried out to identify defects
located by ultrasonic examination shall be included in the measurement, for payment
for radiographic examination.

The measurements shall be on running meter basis as per diameter of pipe.
The payment for ultrasonic testing shall be made on the basis of actual weld
length tested. Tests on failed and repaired specimens shall not be paid.
540
12.10 SPECIFICATIONS FOR SAND BLAST CLEANING(Item No. LIPDN 19)
Cleaning the surface of rising main pipe by Sand Blasting to expose fresh metal
surface ready for painting including removal of all rust, oil, grease, etc. as per
specification including all material, labour and equipments etc complete.
The work includes cleaning of inner and outer surface of the pipe shells, specials
etc. by sand blast cleaning process to remove all rust, mills ate etc. and exposing the
base metal to white gray surface.
Quantity of sand required for blasting shall be 3 cum/ 100 sq .mtr area. Blasting
should be done at a pressure of 5.62 Kg/cm2 at the compressor end and 4.93 Kg/ cm2
at nozzle end so as to get a good cleaned surface after removing the rust. This
pressure should be maintained. Improper jointing of hose pipes and resultant
reduction in pressure at nozzle end shall be checked and avoided. The sequence and
the program of blast cleaning and application of zinc rich Epoxy Primer shall be
arranged in such a way that blast cleaned surface shall not remain uncovered with
zinc rich epoxy Primer for more than 2 hours. Greater care shall be taken in blasting
particularly at field joints for getting Grey surface. After cleaning, the blasted surface
shall be inspected to see that no rust is left out. Primer coat shall then be allowed to be
applied. Torches may be used toinspect the surface.
The percentage of different sizes of sand particles for efficient sand blasting shall be as
Size Percentag
e
8 mesh per inch (25.40 millimeters)... 26

For effective sand blasting it is essential that pressure of air should be between 90 to
100 pounds per square inch (6.33 to 7.03 kilograms per square centimeter). If
pressure falls below 90 pounds per square inch (6.33 kilograms per square
centimeter), sand blasting becomes in effective. If sand having large percentage of
fines is used, it will not provide the requisite cutting power and the whole effort goes
waste. A good quality well graded "sand -blast-sand” is needed for achieving the
objective of sand blasting
541
(i) All oil and grease on the surface of the pipe shall first be removed by applying a
suitable metal cleaning solution and wiping with clean rags. All foreign matter which
cannot be removed by this blasting process shall be removed by any other suitable
means approved by the Engineer-in-Charge all metal surfaces shall be thoroughly
cleaned by blasting. Blasting operations shall remove all rust, scale and other
impurities from the surface exposing the base metal over all presenting a grayish
appearance, however, slight shadows, stacks or discoloration caused by rust stain or
mill-scale oxide need not be removed. Blast cleaned surfaces that rust before a
priming coat could be applied shall be cleaned of all rust by wire-brushing or if
directed by the Engineer-in-Charge they shall be re-blasted at contractor's cost. The
blast cleaned surface shall be primed immediately after blasting is over. The
contractor shall avoid strictly keeping the prepared steel surface overnight and
painting into next morning.
(ii) The record entry of the blast cleaning and before applying primer coat shall be
done and got certified by Engineer-in-Charge.
(iii) The primer coat shall be applied on the very same day within 4 hours from
blast cleaning. If the primer coat is not applied in permissible time sand blasting
will have to be repeated on the next day.

The measurement shall be taken on surface area in square meter basis.
12.10.6.1 MODE OF MEASUREMENT AND PAYMENT:

The payment shall be made after cleaning the surface with sand blasting process.
542
12.11 SPECIFICATION FOR EPOXY PAINTING (Item No. LIPDN 20)
Providing & applying Liquid epoxy coating system to the external surface of
Rising Main Pipes as per Annex - B of IS 3589:2001, preferably by airless spray with
one coat of Zinc rich epoxy primer (90% zink
,DFT 40 micron , coverage 9 Sqm / lit) and two coats of coal tar epoxy paint (DFT
120 X 2 micron coverage 5 Sqm/Lit/coat) including cleaning the surface to the
satisfaction of Engineer in charge by sand blasting
/chemical cleaning / scraping removing oil, grease, other foreign materials including
all necessary material, labour with all leads and lifts etc. complete.
After the shop hydraulic testing the sand blast cleaning shall be done internally &
externally. After the sand blast cleaning the internal surface shall be painted with
licquid epoxy paintand with one coat of Zinc rich epoxy primer (90% zink ,DFT 40
micron , coverage 9 Sqm / lit) and two coats of coal tar epoxy paint (DFT 120 X 2
micron coverage 5 Sqm/Lit/coat) . Where the blast cleaning is not possible the
surface shall be cleaned manually by wire brushing, scraping and with the help of
cleaning solutions.
12.11.4.1 Primer quality
The primer shall be of Zinc Rich Epoxy Primer(90% zinc DFT 40 micron) conforming
to the specifications given.
Before applying the primer the contractor shall submit the manufacturer's test report.
Also the contractor shall arrange for the tests specified or shall arrange for third party
inspection from one of the following services at his own cost. 1) Engineers India
Limited, Bombay 2) R.I.T.E.S. (Rail India
Technical Economic Services, Bombay).
Specification for Zinc Rich Epoxy Primer:
(a) Description: Two pack Zinc Rich consisting of
(i) Base: Fine Zinc Dust ground in Epoxy Resin solution, supplied in paste from.
(ii) Catalyst Adduct Type : The non-volatile portion of the material (mixed)
should consist of 90-92% Zinc Dust and 8-10% of Epoxy Resin and curing
agent.
(b) Shade: Gray
(c) Characteristics :The paint shall provide a complete rust inhibitive barrier
543
coating of high mechanical and abrasion resistance. The film shall be compatible for
fusion and spot weld.
(d) Pot-Life: 4-6 hours
(e) Covering Capacity: 8-10 Sq.m./Liter per coat giving a film thickness of one mm.
(f) Mixing Ratio: The proportion of mixing base and hardener should be as
specified by manufactures by weight or by volume. The mixed primer shall
conform to the specifications detailed under... (a) to (k)
(g) Viscosity of ready mixed paints: 15 to 22 in Ford Cup No. 4 at 30 degrees

Centigrade,
(i) Application: To be applied by spray over a properly cleaned surface, within four
hours after blast cleaning.
(j) Drying Time:
• Dust-free-10-15 minutes,
• Chemical Curing-24-28 hrs.
12.11.4.2 Specifications external surface
The Paint shall be coal tar epoxy paint (DFT 120x2 micron, coverage 5 sq. meter /liter
/ coat )
(a) Grinding and Mixing :
The paint shall be thoroughly ground and in such condition that stirring readily
produce a smooth uniform mixture of such consistency that the paint works well
under the brush. It shall be free from skin and gritty particles, the residue on 240
mesh B.S. Sieve not exceeding 1%
(b) Colour, Capacity, Finish & Consistency :
The paint film, prepared in the manner described in the IS 101-1964 (or latest
revision) for paints, after drying for 48 hours, shall satisfy the requirements in colour
capacity and finish (i. glossy, smoothening of surface freedom from runs, specks).
(c) Fastness to Light:
The change in the colour of the dried paint film will be tested in the manner described
in Clause No. 12 of the IS : 101-1964 (or latest revision) for paints and shall met with
the requirements.
d) Water:
The paints shall not contain more than 0.5% to 1% of water as determined in the
manner describe in ClauseNo. 14 of the IS 101-1964 for paints.
(e) Flash Point:
The flash point abel Closed Test shall not be below 35 degrees Centigrade (95 degrees
544
Fahrenheit.) unless it is not possible to have this flash point on account of the quality of
controlled raw materials.
(f) Drying Time :
The paint when tested on a steel plate shall become surface dry in between 4 and 12
hours and hard dry is not more than 24 hours and tack free dry is not more than 48 hours
as per IS 101.
(g) Resisting Properties :
The paint shall afford a highly durable protective-air-tight coating to prevent

corrosion or rust of iron and steel against air, moisture steam and shall be of sufficient
elasticity to prevent its cracking, blistering or peeling.
(h) Covering Capacity :
The covering capacity for all the types of paint shall not be more than 13.5 Sqm. per lit.
(i) Physical Properties:
The paint shall remain liquid and retain its consistency at the ordinary atmospheric
temperature when packed in suitable containers. After application and drying, the
paint shall not show any surface crack due to weathering action or expansion and
contraction. The paint shall be able to resist the action of acid and alkalis after
application and shall keep properties for not less than one year.
12.11.4.3 Specifications for Red-Oxide of Iron Paint
(a) Composition:
The ready mixed paint for the base coat shall have red oxide base and the
composition of mixed paint shall be as follows:
Mixed pigment dry
Should be 55 + 2%
Volatile Not More
than 5%
Driers…. These may be added when necessary in order that the paint may conform
to the requirement. Such driers shall not contain volatile matter other than
Turpentine or White spirit. Resinate drier shall not be used but the drier should be a
Lineleate or Napthenate Linseed Oil The remainder.
(b) Pigment:
The red oxide of iron shall contain not less than 70% of Ferric Oxide (F203) and
shall be free from acids, water soluble iron salts and impurities.
(c) Linseed Oil :
545
The linseed oil shall be of genuine quality prepared from linseed free from turbidity,
sediment and undissolved water. It shall be of such quality so as to get dry within 8
hours and from a film free from stickiness.
(d) Thinners:
The thinners used shall either be turpentine or white spirit of standard quality.
(e) Weight:
The minimum weight in Kg/10 Liter of paint shall be 15.5 Kg within + or - 3%.
Storage of Paint :
The contractor shall make proper arrangements for storing adequate quantity of
paint, duly tested under shed so that it retains all the proportion until such time as it
is actually used. The painting work shall not be held up for want of tested paint. No
paint which has deteriorated in any way, shall be allowed to be used.
If it is found that the paint is damaged or spoiled in any portion of the pipe surface due
to defective handling or stacking in the factory yard or due to carelessness during
transport to the site of laying, the contractor shall scrap, clean, repaint the same at his
cost to the satisfaction of the Engineer-in-Charge.
Specification for covering coat (Graphite Paint)

1. Composition:
(a) Mixed Pigment Dry Not less than 45%
(b) Volatiles... Not less than 10%
(c) Driers... These shall be line-leate or Napthenate, shall not contain volatile matter
other than turpentine or white spirit. Resinate driers shall not be used. -
(d) Linseed Oil The Remainder.
2. Pigment:
The pigment shall contain not less than 50% of white lead and 40% of graphite as per
IS 62/50 the balancebeing barites (pure graphite being 24% min.)
3. Linseed Oil:
The linseed oil shall genuine quality prepared from linseed, free from turbidity
sediment and undissolved in water. It shall have specific gravity of 0.981 to 0.942 at
30 degrees Centigrade, it shall be of such quality as to get dry within 8 hours and
form a film free from stickiness.
4. Thinners:
The thinners used shall either be Turpentine or white spirit of standard quality.
546
5. Weight:
The weight of one liter of paint shall not be less than 1.5 Kg and not more than 2.1 Kg.
6. Colour:
According to Indian Standard Specifications Shade No. 671.
7. Remaining Para’s shall be as per the general specifications as stated above.
12.11.4.4 Testing of Paint
(a) The general specifications for paints and the further specifications for red oxide of
iron paint are given as above. One sample from each consignment of paint consisting of
maximum 1000 liters. shall be got approved from one of the third party as listed below
at the cost of the contractor, a) Engineers India Limited. Bombay. b)
R.I.T.E.S. (Rail India Technical Economic Services, Bombay). If the test is
satisfactory the consignment shall be passed for use. If it fails two more sample from
two other separate drums shall be taken for test and. only if both the sample are found
satisfactory, the consignment shall be accepted for use. Even if one of the two
samples, fails, the whole consignment of the paint shall be rejected and the contractor
shall remove the same from his works within three days of the intimation from the
Engineer-in-Charge to do so. If the rejected consignment is not removed within the
specified time the Engineer-in-Charge may remove the same at the contractor's risk
and cost and no responsibility shall attach to him as regards its safe custody thereafter.
The entire cost in connection with testing all the samples of paints. Whether satisfactory
or otherwise, shall beborne by the contractor.
(i) Field tests :
a. Inspection of film thickness
The contractor shall provide at site, Elecometer or other standard measuring

devices for measuring film thickness of finished paint. If the thickness is found to
be less than specified, the pipe shall be resurfaced to bring the same to the specified
thickness.
b. Field test for Adhesion :
(i) Two parallel knife cuts about 100 mm long and 20 mm apart shall be made
through the coating. It is permissible to heat the test knife to make the cut when
necessary. The painted surface between the two cuts shall be lifted off the pipe
surface with a stiff blade. If the paint film does not peel off more than the width of
the cut, the paint shall be deemed satisfactory. Should the width of peel exceed the
width of the cut, two additional test shall be made on the same pipe at two deferent
location. Alternatively, any other test mutually agreed upon may be conducted.
(ii) The painted surface shall be accepted if both the tests are satisfactory if
however, the results of either or both of the tests are unsatisfactory the painting
work shall be rejected.
547
Blasted steel surface of the pipes shall be cleaned of dust and grit and shall be
primed immediately following cleaning. The surface shall be dry at the time the
primer is applied and no primer shall be applied during rain or fog unless protected
weather by suitable housing and subject to the permission the Engineer-in- Charge.
The primer shall be applied by hand spray and shall be in accordance with the
instructions for application as supplied by the manufacturers. The priming coat shall
be uniform and free from floods, runs, sags, holidays, drips or have spots. Any/bare
spots or holidays, shall be recoated with an additional application of the primer. All
runs, sags, floods or drips shall be removed or all such defects "shall be remedied by
re- blasting and re-priming at the discretion of the Engineer-in-Charge.
12.11.5.1 Inspection and Testing of Primer
(i) Each tot of primer and heavy duty paint supplied shall be accompanied by
the certified copies of the results of the test carried out by the manufacturers.
(ii) The entire procedure of applying the paint as specified will be rigidly inspected
right from blasting stage to the application of the final coat. If at any time it is found
that the procedure of applying the paint is not as per the standard laid down all such
painting work done shall be rejected.
(iii) Samples of the paint as brought by the contractor shall be sent to the Testing
Laboratory as directed by the Engineer-in-Charge for testing as specified. If any
sample is found to be not conforming to the specifications, the entire consignment
to which the sample may pertain shall be rejected. Samples shall be taken at
intervals at the opinion of the Engineer-in-charge. All the costs incidental to such
testing such as the cost of the paint sample, prescribed testing charges and the cost
of transport etc. shall be borne by the contractor.
12.11.5.2 Application of Zinc Rich Epoxy Primer
The Primer shall be prepared as follows,
The primer shall be prepared in the manner and proportion as specified by the
manufacture
The mix of Zinc Rich Epoxy Primer shall be prepared less than 15 minutes before
applying at the work site. No thinner should be added to the ready mixed paints
without the previous approval of the manufactures.

Though the priming coats become dust-free dry in 10-15 minutes finishing
should only be applied after allowing the film to cure at last for 48 hours.
The record entry of primer coat shall be made and got certified by the Engineer-in-
Charge before applying the paint.
548
12.11.5.3 Application of heavy duty paint
(i) After completing blast cleaning and application of one coat of Zinc Rich Epoxy
Primer internally and allowing curing of primer for 48 hours, the surface of the pipes
should be cleaned by duster and inspected. If any rusted portion is found during
inspection the same shall be removed by emery paper and coated with Zinc Rich
Epoxy Primer. When complete section is checked as above first coat of Heavy Duty
Paint shall be allowed. When one coat is applied the date of application of first coat
of Heavy Duty paint should be written on either end of section before applying
heavy duty paint, the paint shall be properly stirred so as to get good mix. if required
the paint drums should be rolled. Care shall be taken to see that no thinner is mixed
in the paint.
(ii) The painting shall be done by cross brushing, i.e. on coat is to be given
vertically and the other coat is to be given horizontally so as to get necessary
thickness a good looking surface and also to avoid sagging of paint. In order to
distinguish the second coat from first coat the tint of the second coat should be
changed slightly. Every successive coat of paint shall be given after the lapse of 24
hours of painting previous coat. Before applying next coat the surface shall
properly cleaned by duster. The paint shall be stirred every time before applying
with brush for this purpose mechanical mixer should be used.
(iii) Application of Heavy Duty Paint Under very strong sun or in the early morning
in the winter shall be avoided. A width of 150 mm or as may be decided by the
Engineer-in-Charge from either edges of pipe shall be left unpainted. This width will
be painted with three coats of heavy duty paint over one coat of Zinc Rich Epoxy
after ordinary cleaning.
(iv) After completing 3 coats inspection of paint thickness shall be done as per
specifications. The adhesion test as per specifications shall also be carried out.
(v) The covering capacity of paint shall be checked by taking into account the actual
consumption of paint of site by dividing the areas painted by the quantity of paint
actually consumed. For this purpose it is necessary to maintain at site a register of
supply, consumption of paint, the area of surfaces painted another relevant detail as
per Engineers requirements. A separate register shall be maintained for each
category of paint.
12.11.5.4 Ordinary cleaning and painting
(A) General:
(i) The work of ordinary cleaning and painting of pipe, specials such as bends,
tapers, etc. under this contract shall comprise of cleaning and painting internally.
Similarly the contract includes cleaning and priming followed by one coat of red-
oxide of iron paint for pressure and non-pressure type blank flanges, ladders,
platforms, saddle pieces.
‘T’ Branches, manholes covers, other fabricated appurtenances and odd size or shaped
specials not covered above.
(ii) All pipes and other materials to be cleaned and painted shall first be jointly
549
examined by the contractor and the Engineer-in-Charge to see that the fabricated
material is finished in a workman like manner in all respects. If any tacks or other
protrusions are noticed (whether from inside or outside), the same shall be chipped of,
care being taken to ensure that no part of the parent metal gets removed. If in spite of
all the care taken some parent metal gets chipped of, the same shall be repaired by
depositing weld metal and grinding and polishing the surface to the satisfaction of the
Engineer-in-Charge.
(iii) The surface to be painted shall be thoroughly cleaned by using scrappers and
wire brushes to remove all rust mill scale, etc. to give a shining metallic surface. The
surface so cleaned shall be washed with water and allowed to dry. A metal cleaning
solution of approved make shall then be applied over it. After it is dry the surface
shall again be washed with water scraping with wire brushes simultaneously. A use
of water is necessary at this stage to ensure that the metal cleaning solution is
completely removed. After the washed surface is thoroughly dry, a primer coat of
red oxide of iron shall be applied, the primer coat shall be followed by another coat
red oxide of iron.
(iv) The paint shall be applied uniformly so as to give a good finish and the desired
thickness over the entire area covered. The painted pipes shall not be disturbed for a
period of at last 24 hours to allow the paint to dry. At the end of each pipe shall a
length of about 150 mm shall be left unpainted to allow for the damage, when field
welding of joints is done. The ends of pipes which are ordinary cleaned and painted
with heavy duty paint will be paid for under the item of combined rate for clearing and
painting.

The measurement shall be taken on sqm. Basis

. The payment shall be made after, cleaning the surface, application of one coat of
primer and application of two coats of coal tar epoxy paint.
550
12.12 SPECIFICATION FOR INTERNAL EPOXY PAINTING (Item No LIPDN
21)
Providing & applying Liquid epoxy coating system to the interior surface of Rising
Main Pipes as per Annex
- B of IS 3589:2001, preferably by airless spray with one coat of Zinc rich epoxy
primer (90% zink ,DFT 40 micron , coverage 9 Sqm / lit) and three coats of coal tar
epoxy paint (DFT 120 X 3 micron coverage 5 Sqm/Lit/coat) including cleaning the
surface to the satisfaction of Engineer in charge by sand blasting
/chemical cleaning / scraping removing oil, grease, other foreign materials including
all necessary material, labour with all leads and lifts etc. complete.
After the shop hydraulic testing the sand blast cleaning shall be done internally
&. After the sand blast cleaning the internal surface shall be painted with licquid
epoxy paintwith one coat of Zinc rich epoxy primer (90% zink ,DFT 40 micron ,
coverage 9 Sqm / lit) and three coats of coal tar epoxy paint (DFT 120 X 3 micron
coverage 5 Sqm/Lit/coat) . Where the blast cleaning is not possible the surface shall
be cleaned manually by wire brushing, scraping and with the help of cleaning
solutions.
Same as for external paint Sr No.12.11.3
Same as for external paint Sr No.12.11.4

The measurement shall be taken on sqm. Basis

. The payment shall be made after, cleaning the surface, application of one coat of
primer and application of three coats of coal tar epoxy paint.
551
12.13 SPECIFICATION FOR GUNITING OF PIPES (Item No LIPDN 22)
Providing and guniting in CM 1 : 3 (cement consumption 15.94 kg/sqm)

pnumatically under pressure of 2.1 to 2.8 kg /Sq cm, with weld mesh 50 x 50 x 2.54
mm (13 gauge), after duly cleaning the surface by wire brushing, degreasing etc.,
including necessary admixtures (200 ml / bag of cement), curing, rehandling the pipe
from fabrication shop to guniting place and from guniting place to laying location
etc. complete with all leads & lifts.
The item includes blast cleaning the surface and cost of all work, labour supply of
materials including providing and fixing of reinforcement, providing and fixing
spacers, removing and stacking of rebound etc. and also guniting of joints in
trenches.
Portions of the pipeline are to be laid underground shall be out coated with
gunite. The guniting is to be carried out at the site of laying by supporting the pipe
temporarily above ground. Care shall be taken to see that the pipes are perfectly
circular while the out coating is being given.
This shall be done by providing adequate number of spiders. Spiders should not
allowed to be dislodged until the pipeline is laid in position in the trench and
jointed.
The gunite shall be done at least 24 hours before the pipe is lowered into the trench,
but the guniting shall start within four hours from blast cleaning. The cement
consumption shall be 15.94 kg/sqm. and percentage of rebound shall not be more
than 40 %. The thickness of gunite shall be 25 mm. with 2 mm tolerance on either
sides with cement mortar 1:3
12.13.4.1 Reinforcement
The reinforcement used shall be welded mesh 50 mm x 50 mm of 13 gauge. The steel

used shall conform to relevant IS. The welded mesh shall be bent to proper shape to
conform as early as possible to the surface of the pipe, to encased and it shall be
securely held about 20 mm out from the surface of the pipe by means of spacers
made from cement mortar 1:1 and binding wire. Spacers should be placed at least 30
mm. c/c both ways adjacent mesh shall lap at least 200 mm and shall be securely
fastened together binding wire at intervals not exceeding 300 mm.
12.13.4.2 Proportion of mix
The proportion of cement and sand shall be 1:3 by mass.
552
12.13.4.3 Other materials
The materials shall confirm to the specifications prescribed for cement, sand and water
under concrete work.
i) Before guniting all steel surfaces shall be thoroughly cleaned of paint, rust, scales,
grease, loose or disintegrated concrete or such other material as are likely to impair
the bond between the surface to be encased and the gunite, blast cleaning as per the
procedure specified. After blast cleaning the record entry or the same shall be made
and got certified by Engineer-in-Charge before guniting is started. The guniting shall
be done within four hours from blast cleaning. If it is not done in specified time the
blast cleaning will have to be done once again.
The pressure in the lower chamber of the "Cement Gun" shall be sufficient to produce a
nozzle velocity of 115/150 meters per second when a tip with 19 mm opening is used.
The velocity shall be steady at all times.
ii) The compressor used shall be of an adequate capacity to maintain a pressure of at

least 2.1 to 2.8 Kg/cm2 at the gun end.
The nozzle shall be held at such a distance (2/3 to 1 meter) and position that the
stream of flowing materials shall impinge as nearly as possible at right angles to the
surface being gunited. All deposit of loose sand shall be removed prior to placing the
layer of gunite. Should any deposit of and be covered with gunite, this gunite shall
be removed and redone.
iii) The gunite shall be shot in one coat to the proper thickness. At the edge of any
section where operations are more or less temporarily suspended the gunite shall be
brought to a tapered edge extending back for not less than 30 cm. Prior to placing the
gunite on the adjacent section the upper surface of this tapered edge shall be cleaned
by scraping and blowing away all rebound and washing sown with water and air blast.
No right angled joints shall be allowed in the gunite.
iv) The contractor shall provide proper arrangements for blowing all rebound from
the area being shot. No gunite shall be placed over rebound and in case of such
conditions arising; the contractor shall remove at his own cost any gunite so placed.
Rebound material deposited in mounds shall be removed from the site of work as
directed by the Engineer-in-charge. Any rebound falling in trench shall be carefully
cleaned with an air jet and suitable tools at such periods after shooting as the
Engineer-in-charge may deem advisable. In no case, however shall the rebound
remain on the completed surface for more than 12 hours. The scraping of rebound
must be done in such a manner as not to disturb the gunite and to provide uniform
and proper finish to the surface.
v) The contractor shall employ experienced man for this work. No nozzle man will
be deemed experienced unless he has done considerable work previously where the
work of a similar type or has otherwise proved his qualifications to the satisfaction of
the Engineer-in-charge by experience on other equally important work.
The work shall be supervised by properly trained foreman of the contractor. No
553
one shall be considered as capable of acting as foreman on a job if he has not had
active charge of placing gunite lining previously.
12.13.5.1 Curing
1) The finished gunite should be cured by continuous and uniform water sprays after
a period of 8 hours from placement and period of at least 21 days after guniting.
2) The compressive strength for 28 days of mortar cube should be at least 105 Kg./cm.2
3) The curing water should be of the same quality as that of mixing water.
4) May be used chemical for curing during the procedure of guniting.

The unit of measurement shall be surface area in square meter basis.
For the purpose of measurement, area shall be calculated on the assumption that
the diameter is 25 mm
larger than the outer diameter of steel pipe.
The payment shall be made after blast cleaning the surface, labour supply of
trenches.
554
12.14 SPECIFICATION FOR CEMENT MORTAR LINING(Item No LIPDN 23)
Providing inner cement mortar lining of specified thickness in proportion 1:1.5 using
mechanical spinning machine, including all necessary labour, material, plants and
equipments, local handling etc. complete as perprocedure laid down in IS 3589:2001.
The item includes blast cleaning the surface and cost of all work, labour supply of
trenches.
Portions of the pipeline are to be laid underground shall be out coated with
gunite. The guniting is to be carried out at the site of laying by supporting the pipe
temporarily above ground. Care shall be taken to see that the pipes are perfectly
circular while the out coating is being given.
The thickness of lining shall be 9 mm to 12 mm with cement mortar 1:1.5
12.14.4.1 Proportion of mix
The proportion of cement and sand shall be 1:1.5 by mass.
12.14.4.2 Other materials
The materials shall confirm to the specifications prescribed for cement, sand and water
under concrete work.
i) Before lining all steel surfaces shall be thoroughly cleaned of paint, rust, scales,
grease, loose or disintegrated concrete or such other material as are likely to impair
the bond between the surface to be encased and the lining, blast cleaning as per the
procedure specified. After blast cleaning the record entry or the same shall be made
and got certified by Engineer-in-Charge before lining is started. The lining shall be
done within four hours from blast cleaning. If it is not done in specified time the blast
cleaning will have to be done once again.
ii) The contractor shall employ experienced man for this work. No nozzle man will
be deemed experienced unless he has done considerable work previously where the
work of a similar type or has otherwise proved his qualifications to the satisfaction of
the Engineer-in-charge by experience on other equally important work.
The work shall be supervised by properly trained foreman of the contractor. No
555
one shall be considered as capable of acting as foreman on a job if he has not had
active charge of placing lining previously.
12.14.5.1 Curing
1) The finished lining should be cured by continuous and uniform water sprays after
a period of 8 hours from placement and period of at least 21 days after guniting.
2) The compressive strength for 28 days of mortar cube should
be at least 105 Kg./cm.2 3)The curing water should be of the
same quality as that of mixing water.
4) Chemical may be used for curing.

The unit of measurement shall be surface area in square meter basis.
For the purpose of measurement, area shall be calculated on the assumption that
the diameter is 9mm to12mm smaller than the inner diameter of steel pipe.
12.14.6.1 MODE OF PAYMENT :
The payment shall be made after proper inspection by Engineer ingharge
556
12.15 SPECIFICATION FOR WELDING(Item No LIPDN 24)
Providing 'X' Ray Quality M.S. Welding in all positions with required number of
runs, for M.S. pipes internally and / or externally including gauging wherever
necessary, fixing appurtenances and other accessories in connection with pipe laying
work as per specification, using electrodes having weldmark E7018 (Low hydrogen
electrodes), including Surface preparation, (i.e. Removal of scale, cleaning, etc.)
including all materials, labour, equipments, etc. complete.
The work of welding includes tack welding, gauging wherever necessary, fixing
appurtenances and other accessories in connection with pipe laying work as per
specification, Surface preparation, (i.e. Removal of scale, cleaning, etc.) including all
materials, labour, equipments.
Welding Electrodes :-
The electrodes (Low Hydrogen Electrodes having weld marks ET018) shall
conform to I.S. 814-2004 [specifications for covered electrodes for metal arc
welding of mild steel].
In order to maintain a good standard in welding, welders shall be tested by the

contractor before they are entrusted with the job. The welders shall be sufficiently
experienced in welding works to execute works of standards specified in I.S.817 -
1966 . The welder will weld two pieces of flat plates cut out of the plates to be used
on this work together to make test pieces of his welding work. These pieces will be
welded with same electrodes and under the severe conditions exactly similar to those
under which he will be require to weld the pipes and in the most difficult physical
position he would be forced to take for such welding of the pipe. Each test piece so
prepared, will be cut by a milling cutter into three test pieces after rejecting some
portions at the end and then tested as under.
(a) One test piece for tensile strength to determine the braking strength. The
minimum breaking strength specified for the parent plate shall be attained by the
weld in this test.
(b) Two bending test pieces with the weld bend in the middle. These test pieces shall
withstand /without damage exactly as the metal in the parent plate parallel bending
with d=3t where 't’ is the thickness of the plate and ’d’ the internal diameter of the
bend.
Tensile strength test and bending test of weld shall be done for one pipe length per 10
pipe length of weld.
The above test shall be done for each welder and wherever there is change in the lot
of welding rods and weld materials. A periodical test as regards their efficiency shall
557
also be taken at intervals of about 6 months and those found inefficient shall be
removed from the job. Those who pass the test only shall be posted on the job.
A record shall be maintained showing the names of welders and operators who have
worked on each individual joint. Hand welding when required shall preferably be
carried out by a pair of welders so that by observing proper sequence distortion can be
avoid A joint trusted to a particular individual or a pair shall be as far as possible,
completed by them in all respects, including sealing run. No helper or other
unauthorized person shall be permitted to do any welding what so ever. In case of
infringement of above the persons shall be punished as directed by the Engineer-in-
Charge.
The Welding of pipes-in the field shall comply with IS 3589-2001 and 816-1969
(code) of practice for use of metal arc welding for general construction in mild steel).
And shall be paid on running meter basis.
The openings in the laid pipe line if required in the form of manholes made at
suitable distances, for access into the pipeline for the work of cleaning, painting and
repairs to the welds etc. shall be closed by welding anew patch on the opening.
Such manholes should, as far as possible be provided at the sides of pipelines,

cutting at the crown of the pipe should be avoided, as far as possible. The following
procedure should be strictly adopted while plugging the manholes by Patch plating.
(1) The manholes shall be plugged by providing a patch plate cut from a separate
strake of pipe of the same dia. The old plate cut from the pipeline shall not be used
for this purpose.
(2) The edges of the new patch plate shall be properly shaped and the same shall be
inserted in the opening bykeeping a gap of 3 to 4 mm and tacked.
(3) The welding of the patch plate should be done in segments with proper
sequence conforming to IS 623- 2008 or in sequence 1-3-2-4 as per B.S.S.
practice.
12.15.5.1 Testing of welded joints
Welded joints shall be tested in accordance with procedure laid down in Indian
Standard Specifications IS.3600. (Code of Practice for Testing Fusion Welded Joints
and Weld Metal in Steel).
At least one test specimen shall be taken out for testing, per ten joints done. Test
pieces shall be taken out from the places pointed out by the Engineer. They shall be
machined and tested as early as possible. The shape of the test pieces removed for
testing shall be such that it shall give the specimen of the required dimensions with the
weld in the middle of the specimen and the same time leaves the hole in the pipe -
with rounded corner.
This hole shall be patched plated with a plate of suitable size cut from a separate
pipe of same diameter. It must ensure good butt weld.
12.15.5.2 Tensile test
558
The test specimen taken perpendicularly across the weld shall be shaped in
accordance with Indian Standard Specifications IS: 2062-2011. The tension test
specimen shall be machined. The protruding welded portion from inside as well as
outside shall be removed by machining before the specimen is tested. If the specimen
shows defective machining or developing flaws not associated with welding, it shall
be discarded and another specimen substituted. The welded joint shall show strength
not less than the minimum tensile strength for the plate in accordance with IS: 2062-
2011.
Tensile strength test of weld shall be done for one pipe length per 10 pipe length of
weld.
12.15.5.3 Bend test
Bend test specimen shall also be prepared in the same fashion as the tensile test
specimen. The specimen shall stand being bend cold through 180 around a pin that
has a diameter equal to 4.5 times the plate’s thickness without developing cracks. For
(this test, face representing inside of the pipe shall be placed next to the pin.
Test frequency/quantity for Bend test in accordance with IS: 2062-2011 para11.1
12.15.5.4 Pre-planned plugs
Pre-planned plugs shall be taken out from any welded portion as pointed out by the
Engineer. These plugs shall not show any defects in welding such as inclusion of
slag, below holes, cavities, etc. The plug shall be 12 mm in diameter and shall be
taken out by means of suitable electrically operated hole-saw. Such holes in the pipe
shall either be filled back by inserting a steel stud and welding around or threading
the hole and providing suitable G.I. plus. This test shall be done only if considered
necessary by the Engineer.
12.15.5.5 Procedure on failure of the specimen
If the test specimen fails to either tensile or bend test or in both, two additional test
specimen shall be taken out from the same section and shall be tested for tensile and
bend tests. If any one of them fails, extensive gouging and re-welding shall be done for
the welded joints in that section to the full satisfaction of the Engineer.
However, if both the samples give satisfactory result, the joint from which the
original sample was taken and had failed shall be repaired to the satisfaction of the
Engineer, by gouging and welding etc. at contractor's cost. Welder, who had done the
welding of the joint that has failed, shall be solely held responsible. Since all other
factors like electrodes, current, arc voltage etc. are already controlled, negligence on
the part of the welder only is responsible for such failure. For first such failure the
welder shall be warned and if the welded joint done by him fails for the second time,
he shall be removed from the job.
The expenses of above tests are included in the unit rate of welding and no extra
charges shall be paid for above tests.
559
The payment for welding shall be Rmt.
12.15.6.1 MODE OF PAYMENT :

The payment shall be made after proper inspection by Engineer ingharge
560
SPECIFICATION FOR DUCTILE IRON (D.I.) PIPES (K-7)
12.16 Providing and supplying D.I. pipes (Item No. LIPDN 25)
Providing and supplying D.I. pipes (push on joints pressure pipes of D. I. of following
class and diameters confirming to the I.S. specification inclusive cost of jointing materials
(Rubber gasket of EPDM Quality) excluding GST levied by GOI & GOM in all respect
including Third party inspection charges of TPI Agency approved by WRD including Transit
insurance, Railway Freight, Unloading from railway wagon, Loading into Truck,
Transportation to departmental store, unloading, stacking etc. completed as directed by
Engineer-in-charge (IS 1536-2001 for pipes and IS 158-1969 and IS 12820-1989 or latest
edition/revision with amendments for Rubber Gaskets. (IS:8329-2000 Latest Version) D.I. K-
7.

This specification covers the requirements for providing and D. I. pipes(push on joints
pressure pipes of D. I. of following class and diameters confirming to the I.S. specification
inclusive cost of jointing materials (Rubber gasket of EPDM Quality) excluding GST levied
by GOI & GOM in all respect including Third party inspection charges of TPI Agency
approved by WRD including Transit insurance, Railway Freight, Unloading from railway
wagon, Loading into Truck, Transportation to departmental store, unloading, stacking etc.
completed as directed by Engineer-in-charge (IS 1536-2001 for pipes and IS 158-1969 and IS
12820-1989 or latest edition/revision with amendments for Rubber Gaskets. (IS:8329-2000
Latest Version) D.I. K-7.
• Introduction
Ductile iron (DI) pipes are manufactured from ductile iron. Ductile iron is a type of
iron in which graphite is present primarily in spherical or nodular form.
The Contractor shall provide on-site training on DI pipe laying, jointing, testing and
maintenance etc., to the personnel authorized by the Engineer-in-charge. The contractor
should provide technical Manual on DI pipes including precautions to be taken during
operation of the pipeline.
• Applicable IS Codes
The manufacturing, testing, supplying, laying, jointing and testing at work sites of DI
pipes shall comply with all currently applicable statutes, regulations, standards and Codes.
In particular, the following standards, unless otherwise specified herein, shall be referred.
In all cases the latest revision of the Codes shall be referred to. If requirements of this
Specification conflict with the requirements of the standards/Codes, this Specification
shall govern. Others Codes not specifically mentioned here but pertaining to the use of
PSC Pipes form part of these Specifications.
IS 8329 Centrifugally cast(spun) ductile iron pressure pipes for water, gas
and sewage
IS 9523 Ductile iron fittings for pressure pipes for water, gas and sewage
IS 12288 Code of practice for use and laying of Ductile Iron pipes
IS 11606 Methods for sampling of Cast Iron pipes and fittings
IS 5382 Rubber sealing rings for gas mains, water mains and sewers
561
IS 638 Specification for Sheet Rubber Jointing and Rubber Insertion Jointing
IS1608 Mechanical testing of metals -tensile testing
IS1500 Methods for Brunel hardness test for metallic materials
• Raw Materials
Raw material used in manufacturing of pipes (with or without coating) is ductile iron,
cement, sand, water, zinc, bitumen, polyethylene and rubber gasket.
Ductile Iron : The general requirements relating to the supply of DI metal used in pipe
manufacturing shall be as per IS 1387 and IS 8329. The metal used for the manufacture
of pipes shall be of good quality commensurate with the mechanical requirements
specified in IS8329.
Cement : The cement used for the pipe lining shall conform to the existing standards of
cement. Following types of cement can be used for lining.
a) Ordinary Portland cement conforming to IS 8112 or IS 415.
b) Sulphate resisting Portland cement conforming to IS 12330 or IS 6909.
c) High alumina cements conforming to IS 6542.
Sand : The sand used shall have a controlled granulometric distribution from fine to
coarser elements. It shall be clean and shall be composed of inert, hard, strong & stable
granular particles. The gradation of sand shall be as specified in IS 8329.
Water : The water used for the preparation of mortar shall not contain substances
deleterious to the mortar.
Zinc : Zinc used for coating purpose is metallic zinc with content of atleast 99 % by mass.
Bitumen: Bitumen used for coating purpose shall be smooth, tenacious and hard as
specified in IS 8329.
Polyethylene: The density of polyethylene shall be between 910 to 930 kg/m³.
Rubber gasket : Rubber gaskets used with push-on joints or mechanical shall conform to
IS5382, whereas rubber gaskets for use with flanged joints shall conform to IS638.
• Manufacturing of Pipes and Specials

• The metal used for the manufacture of pipes shall be of good quality, commensurate
with the mechanical requirements laid down of IS 8329.
• The pipes shall be stripped with all precaution to avoid warping or shrinkage defects,
detrimental to their good quality. The pipes shall be sound and free from surface or
other defects.
• Pipes centrifugally cast shall be heat-treated in order to achieve the necessary
mechanical properties and to relieve casting stresses caused due to the method of
manufacture and repair work.
• If necessary, the pipes may be subjected to reheat treatment to ensure that Brinell
hardness does not exceed the specified value and the other mechanical
properties specified in IS8329 are achieved.
562
The manufacturing process flow of DI Pipe is as given the below.
Pipe Manufacturing Procedure

Molten Iron
Induction Furnace
Spheroidization
Core Making
Centrifugal Casting
Annealing
Zinc Spraying
Grounding & Grinding
Hydraulic Testing
Cement Lining
Cultivating
Bitumen Coating
Packing
• Classification of pipes :
• Pipes have been classified as K7,K8,K9, K10, K12,….depending on service
conditions and manufacturing processes
• The class designation shall comprise of
a) prefix K
b) A whole number used for thickness. class designation
• The wall thickness of pipe ‘e’ in mm shall be calculated as function of the nominal
diameter by the following equation with minimum of 5mm for K=7,6mm for k=8 &
7mm for K=12.
e=K(0.5+0.001DN)
where,
e=wall thickness in mm
DN=the nominal diameter, & K=the whole number coefficient.
• The value of K will depend on following service conditions.
(Reproduced from IS 8329)
Service conditions
Nominal dia. Water Sewers Gas main
Main
80-300 K9-K12 K7-K12 K9-K12
350-600 K8-K10 K7-K10 K9-K10
700-2000 K7-K10 K7-K10 K9-K10
563
• For screwed or welded on flange pipes the minimum classes as per working
pressure criteria are given below.
Coating: DI pipes shall normally be coated externally and internally.

External protection: Depending upon external condition of use, the external protections
can be of following three types as specified in IS 8329.
a) Zinc coating:
• The pipe surface shall be dry and free from rust or any non adhering particles or foreign
matters such as oil or grease. Metallic zinc shall be applied on to the oxide external
surface of the pipe.
• The coating materials are metallic zinc with content of atleast 99% by mass.
• The metallic zinc coating shall be applied by as spraying process, in which metallic zinc
material is heated to molten state & projected in small droplets by spray guns onto
surface. The zinc rich paint coating shall be applied by a spraying or a brush process
onto the pipe surface in case of repairs only.
• The metallic zinc coating shall cover the outside diameter of the pipe and shall be free
from such defects as bare patches or lack of adhesion.
• Damaged areas of zinc coating caused by handling are acceptable provided that the
damage is less than 5cm2/m2 of coated surface & provided that the minor dimensions of
the damaged area do not exceed 5mm.
• The average mass of zinc coating shall be not less that 130g/m 2 with local minimum of
110gm/m2
• After metallic zinc coating or zinc paint coating, the pipe shall be given a finishing layer
of bituminous paint or synthetic resin compatible with the zinc coating.
• Applications of the finishing layer may be done by any proven process such as spraying
or brush coating at the manufacturer’s choice. It shall uniformly cover zinc coating and
be free from bare patches or lack of adhesion.
• The mean dry film thickness of the finishing layer shall not be less than 70µm. with
nowhere less than 50µm.
b) Bituminous coating:
• Coating shall not be applied to any pipe unless its surfaces are clean, dry & free from
rust.
• The mean thickness of coating shall be not less than 70µm & the local minimum
thickness shall be not less than 50µm.
• Where the coating material has a bitumen base, it shall be smooth & tenacious and hard
enough not to flow, when expose to temperature of 650 c but not so brittle at a
temperature of 00C as to chip off when scribed with a penknife.
c) External sleeving:
564
• The polyethylene sleeves may be supplied, for encasement of the pipes at site, along
with the pipes if ordered by the purchaser. This encasement shall be so designed that
prevent contact between pipe and surroundings backfill and bedding material.
• The material used for making the film is polyethylene or a mixture of polyethylene and
/or ethylene and olefin copolymers. Its density shall be between 910 & 930 kg/m3.
• If protection against ultra violet rays is required, the material shall be stabilized by the
additions of an appropriate product, if carbon black is used for this purpose the addition
shall be in the range of 2 to 3 % by mass.
Internal lining: Depending upon the internal conditions of use, the internal lining can be of
following two types as specified in IS 8329.
a) Cement mortar lining: The cement used for the lining shall be either ordinary Portland
cement or sulphate resisting port land cement or high alumina cement.
• The mortar of the lining shall be composed of cement, sand & water. Additives, which
shall be specified may be used, provided that they do not prejudice the quality of the
coating & that of the transported water. The mortar shall contain by mass at least 1 part
of cement to 3.5 parts of sand.
• All foreign bodies, loose scale or any other material which could be detrimental to good
contact between the metal & the lining shall be removed from the surface to which the
lining is to be applied. The inner surface of pipe shall also be free of any metal
projections likely to protrude beyond 50% of thickness of the lining.
• The cement mortar lining at works is applied by a centrifugal spinning process or a
centrifuged sprinkler or combination of both methods.
• Lining thickness varies from 3mm to 9mm depending on pipe thickness as specified in
IS8329.
• The surface of the cement mortar lining shall be uniformly smooth. Only isolated grains
of the sand are allowed to appear on the surface of the lining.
• When specified, the cement lining shall be given a seal coat of bituminous material or
any other epoxy base material compatible with cement mortar lining. The purpose of the
seal coat is to minimize lime, leaching of the cement mortar as well as to restrict the
unwanted rise in pH value of the transmitted water.
b) Bituminous paint: The specification for this shall be as given in sub para. (b) of
above paragraph.
• Sampling criteria for Selection of Pipe for Testing Purpose
• In a consignment, all pipes/ fittings of the same class, type and dimensions produced by
a single manufacturing unit shall constitute a lot. Each lot shall be inspected separately
for ascertaining its conformity to the requirements of specification given in IS 8329.
• Each pipe shall be checked for visual characteristic such as surface defect, finish &
position of socket, flanges, threads, collars.
• The lot which has been found satisfactory in respect of visual requirements shall be
tested for dimensional requirements as specified in following paragraph. Numbers of
pipes to be selected from the lot for checking dimensional requirements shall be as per
following Table No.1.
565
Table No.1Scale of sampling and criteria for acceptance for dimensional
requirements of pipes.
Lot size Sample size Acceptance No.
Upto 50 8 0
51-100 13 1
101-150 20 1
151 -300 32 2
301 & above 50 3
• Each of the items selected according to above paragraph shall be inspected for
dimensional requirements. Any item failing to meet above requirements shall be
termed defective. If the number of defectives found in the sample is less than or equal
to acceptance number given in column 3 of above Table 1, the lot shall be deemed as
conforming to the requirements specified. Otherwise, the lot shall be rejected or
subjected to 100 % inspection for the requirements.
• The lot found conforming in respect of dimensional requirements shall then be tested
for mechanical acceptance tests as specified in following paragraph.
• The mechanical acceptance tests shall be carried out on samples of ductile iron pipes
which shall be grouped in following batch sizes.
DN (mm) Maximum Batch Size
80- 250 200 pipes
300- 600 100 pipes
700- 1 000 60 pipes
1 100 – 1 400 40 pipes
1 600 – 2 000 30 pipes
• In order to check compliance with the requirements specified for mechanical

acceptance test, a sample ring or bar shall be taken from the spigot end of pipes.
• For this purpose, the number of tests for mechanical acceptance tests shall be at the
rate of 1 per 4 tones of pipes/ fittings subject to minimum of 2 and maximum of 10
tests.
• Each pipe and fittings shall be subjected to hydrostatic tests in the factory.
• For coating tests, two samples from each test shall be taken at random & subjected to
appropriate tests. These samples shall meet the coating requirements as mentioned in
earlier paragraph.
• If test piece representing a batch fails in the test in the first instance, two additional
tests shall be made on test pieces selected from two other pipes from the same batch.
If both the test results satisfy the specified requirements, the batch shall be accepted.
Should either of this additional test pieces fail in the test, the batch shall be deemed as
not complying with the requirement.
• Pre Delivery Testing of Pipes
Pipe selected as per sampling criteria mentioned in above para 5.0, are subject to following
tests before delivery from factory.
1. Dimension: Critical dimensions, External diameter, Wall thickness, Length of pipe,
ovality, deviation from straight line.
2. Tensile test
566
3. Brinell hardness test
4. Hydraulic test
These tests shall be carried out by the agency in the presence of representative of Engineer
In-charge /WRD/QC/TPI.
• Dimensions:
Various dimensions of pipes shall be as per the relevant tables of IS.8329 for different
class of pipes.
• Critical dimension: Critical dimensions for socket and spigot of pipes for push-on
flexible joints and mechanical joints for classes K7, K8,K9 & K10 are given in the
following table no.2.
Table no.2: Dimensions of sockets & Spigots
All dimensions are in mm (Reproduced from IS 8329)
Nominal External Barrel wall thickness ’e’(mm)

diameter diameter K7 K8 K9 K10
DN (mm) DE(mm)
80 98 5 6 6.0 6.0
100 118 5 6 6.0 6.1
125 144 5 6 6.0 6.3
150 170 5 6 6.0 6.5
200 222 5 6 6.3 7.0
250 274 5.3 6 6.8 7.5
300 326 5.6 6.4 7.2 8.0
350 378 6.0 6.8 7.7 8.5
400 429 6.3 7.2 8.1 9.0
450 480 6.6 7.6 8.6 9.5
500 532 7.0 8.0 9.0 10.0
600 635 7.7 8.8 9.9 11.0
700 738 9.0 9.6 10.8 12.0
750 790 9.7 10.0 11.3 12.5
800 842 10.4 10.4 11.7 13.0
900 945 11.2 11.2 12.6 14.0
1000 1048 12.0 12.0 13.5 15.0
1100 1152 14.4 14.4 14.4 16.0
1200 1255 15.3 15.3 15.3 17.0
1400 1462 17.1 17.1 17.1 19.0
1600 1668 18.9 18.9 18.9 21.00
1800 1875 20.7 20.7 20.7 23.00
2000 2082 22.5 22.5 22.5 25.00
567
• Dimensions of flanged pipes centrifugally cast with screwed on flanges or welded
flanges shall be a part table 3,4,5,& 6 of IS 8329
• External Diameter: External diameter (DE) of the spigot end of socket and spigot
pipes is measured circumferentially using a diameter tape. The positive tolerance for
external diameter is + 1 mm and applies to all thickness classes of pipes. The negative
tolerance of the external diameter depends on the design of each type of joint and
maximum negative tolerance is as specified in following Table No.3
Table 3 External diameter DE (mm)

(Reproduced from 8329)
Dn Nominal Tolerance
(1) (2) (3)
80 98 +1,-2.2
100 118 +1,-2.8
125 144 +1,-2.9
150 170 +1,-3
200 222 +1,-3.1
250 274 +1,-3.3
300 326 +1,-3.4
350 378 +1,-3.5
400 429 +1,-3.6
450 480 +1,-3.8
500 532 +1,-4
600 635 +1,
700 738 +1,-4.3
750 789 +1,-4.4
800 842 +1,-4.5
900 945 +1,-4.8
1000 1048 +1,-5
1100 1152 +1,-6
1200 1255 +1,-6.2
1400 1462 +1,-6.6
1500 1565 +1,-7
1600 1668 +1,-7.4
1800 1875 +1,-8.2
2000 2082 +1,-9
• Wall Thickness
568
The tolerance on the wall thickness (e) and the flange thickness (b) of the pipes shall
be as follows :
Dimensions Tolerance (mm)
i) Wall thickness -(1.3+0.001 DN)1
ii) Flange thickness (b) ±(2+0.05b)
• Length
The Standard working length of socket and spigot pipes shall be 4 m, 5 m, 5.5m and
6 m and for flanged pipes shall be 4m, 5 m, and 5.5 m. Other lengths are available by
agreement between the manufacturer and the purchaser.
The tolerance on length of pipes shall be as follows:
Type of Casting Tolerance(mm)
i) Socket and spigot and plain ended pipes ± 100
ii) Flanged pipes ± 10
• Ovality: Out of roundness of a pipe section; it is equal to 100 {(A1-A2)(A1+A2)},

where A1, is the maximum axis and A2 the minimum axis of the pipe cross-section.
• Pipes shall be as far as possible circular internally and externally. The tolerance
for out-of-roundness of the socket and spigot ends in the jointing zone for push-
on-joint is given in following Table 4 and for mechanical joint is given in
following Table 5
Table 4: Allowable ovality for push-on-Joint Pipe.

Nominal Diameter Allowable Difference between Minor
DN Axis and DE, Min
(mm) (mm)
(1) (2)
80 to 300 1.0
350 to 600 1.75
700 2.0
750 to 800 2.4
900 to 1000 3.5
1100 to 1200 4.0
1400 to 1600 4.5
Table 5: Allowable ovality for Mechanical Joint Pipe

Nominal Diameter Maximum Ovality of Spigot of External
DN Diameter DE
(mm) (mm)
(1) (2)
80 to 150 5
200 to 350 10
400 to 500 20
600 to 800 30
900 to 1000 40
1100 to 1400 50
1600 to 2000 60
569
• Deviation from a straight line: The pipes shall be reasonably straight when the pipe
is rolled along gantries, separated by distance approximately two-thirds the length of
the pipe to be checked, the maximum deviation from a straight line in mm shall not be
greater than 1.25 times the length L, in meters of the pipe;
• Tensile Test:
• The thickness of the sample and the diameter of the test bar shall be as given below.
Castings Thickness Test Bar, Test Bar, Method B
(mm) Method A Nominal Nominal Tolerance on
Nominal Area Sₒ Diameter Diameter
2
Diameter (mm ) (mm) (mm)
(mm)
Centrifugally Cast
Pipes :
--- less than 6 2.5 5.0 2.52 0.01
---6 up to but not 3.5 10.0 3.57 0.02
including 8
---8 up to but not 5.0 20.0 5.05 0.02
including 12
--- 12 and over 6.0 30.0 6.18 0.03
• A Sample shall be cut from the spigot end of the pipe. This sample may be cut
perpendicular to or parallel with the pipe axis, but in case of dispute the parallel to
axis sample shall be used.
• A test bar shall be machined from each sample to be representative of the metal at
the mid-thickness of the sample.
• The test bars shall have a gauge length at least five times the nominal test bar
diameter. The ends of the test bars shall be such that they will fit the testing
machine.
• Two methods of measuring the tensile strength are method A or method B as
explained below:
Method A—Machine the test bar to its nominal diameter +/- 10 percent, measure the
actual diameter before the test with an accuracy of 0.01 mm and use this measured
diameter to calculate the cross- sectional area and the tensile strength.
Method B—Machine the test bar to its nominal area Sₒ within a specified tolerance on
diameter and use the nominal area to calculate the tensile strength.
• The sample shall be tested as per procedures laid down in IS 1608. The test results
shall satisfy the following requirements.
Nominal Diameter Minimum Tensile Minimum Elongation at

(DN) (mm) strength (MPa) break (%)
80-1000 420 10
1100-2000 420 7
• For ductile iron pipes up to DN 1000, if the tensile strength of specimen is not
found within limits, and microstructure reveals 75 percent ferrite with spherical
570
graphite and percentage elongation ≥7, it shall be taken as meeting the
requirements.
• Brinell Hardness Test:
When tested in accordance with IS 1500, the Brinell hardness shall not exceed 230
HB on the external un-machined surface.
• Hydrostatic Test:
• All pipes shall be tested hydrostatically at a pressure specified in following Table
no.6. To perform the test, pressure shall be applied internally and shall be steadily
maintained for a period of 10sec. The pipes shall withstand the pressure test and
shall not show any sign of leakage, sweating or other defects of any kind.
• Test shall be carried out before the application of surface coating and lining.
Table no.6 Hydrostatic Test Pressure
Nominal Minimum Hydrostatic Test Pressure at Works, MPa
Diameter Centrifugally cast pipes Pipes with screwed or welded on
(DN) (mm) with flexible joints flanges
Class Class Class PN PN 16 PN 25 PN 40
K7 K8 K9, 10 Flange Flange Flange
Class Flan
K10, ge
Class
K12
(1) (2) (3) (4) (5) (6) (7) (8)
80 to 300 3.2 4.0 5.0 1.6 2.5 3.2 4.0
350 to 600 2.5 3.2 4.0 1.6 2.5 3.2 4.0
700 to 1.8 2.5 3.2 1.6 2.5 3.2 --
1000
1100 to 1.2 1.8 2.5 1.6 2.5 2.5 --
2000
• Marking on Pipes
Each pipe shall be indelibly marked in English language at either end of each pipe. The
marking shall show the following.
1. Manufactures name or trademark.
2. Class reference
3. Pressure rating.
4. Nominal diameter
5. Lot/batch No. of manufacturer.
6. BIS certification mark.
7. Third Party Certification mark for each lot
8. Name of Department/Project for pipe which pipes are manufactured.
9. Any other important matter that the manufacturer or purchaser deems fit to be
inscribed.
• Transportation of Pipe:
• DI pipes are less susceptible to cracking or breaking or impact but precautions should
be taken to prevent damage to the protective coating.
571
• Pipes should be loaded in such a way that they are secured and that no movement
should take place on the vehicle during transit.
• The pipes should be loaded on vehicles in pyramid or straight sided formation. In case
of pyramid loading, the pipes in the bottom layer should be restrained by the use of
broad wooden wedges secured to the vehicle being loaded. The pyramid is to be
formed by resting pipes between the pairs of pieces in the preceding layer with the
sockets in layers reversed. Straight sided loading may be used with supports along the
sides of the vehicles. The use of straight sided loading is advantageous for utilizing
full capacity of the vehicle.
• Cranes should be preferred for off-loading. However, for pipes up to 400 mm nominal
bore, skid timbers and ropes may be used.
• When using mechanical handling equipment, it is necessary to employ sufficient
personnel to carry out the operation efficiently with safety. The pipes should be lifted
smoothly without any jerking motion and pipe movement should be controlled by the
use of guide ropes in order to prevent damage caused by pipes bumping together or
against surrounding objects.
• Where the crane operator does not have a clear view, he should be guided by the
personnel supervising the operation. The hooks should be of suitable shape to ensure
positive engagement when entered into the ends of the pipes and then should pass over
any protective packing fitted around the pipe ends.
• The use of slings passed around bundles of pipes is not recommended because bundles
become unstable as the sling is drawn tight or released. However, when it is necessary
to use the central slinging method for lifting single pipe, a broad webbing sling is
recommended which minimizes the risk of the pipe slipping.
• Stacking of Pipe at Site

• The first layer of pipes should be laid on a firm foundation consisting of solid timbers
set level on the ground. Subsequent layers should be placed according to the method
of stacking adopted. Care should be taken so that the pipes do not rest on their sockets.
The height of any stack should not exceed 2 m. Stacking of pipes can be either square
or parallel or nested as explained below.
572
Methods for Stacking of Pipes
Square Stacking Parallel Stacking with timbers Nested (Pyramid) Stacking
nd
▪ 2 and subsequent ▪ All the pipes are parallel with ▪ Nested stacking consists
layers are set at right the sockets of successive of placing each pipe
angles to previous layers reversed end-to-end between the two pipes
layer with spigots & with sockets projecting underneath it, with the
sockets alternating in beyond spigot end. sockets being all at one
each layer & sockets ▪ Timber battens placed about end of each layer & being
project beyond spigot 600 mm from each end at reversed in successive
end. right angles to the pipes are layers.
▪ The pipes rest directly used to separate the ▪ The bottom layer should
upon those beneath it. successive layers. be firmly anchored to
▪ Care is needed in ▪ Wedges at both ends of each prevent the stack collapse.
placing to prevent batten prevent pipe
damage. movement.
• Bitumen-sheathed pipes should not be stacked but laid in a single layer supported on
timbers placed under the uncoated portions of the spigots and sockets.
• Valves
For PDN work, various Valves as mentioned below are required to be provided on pipeline
at various locations.
• Air Valve:
The effect of air valve in the long-distance water pipelines are in the following three areas:
firstly, in the waterfilled stage of the pipeline, filled with water by a certain velocity, the
air valve can discharge the remained gas in the pipe; secondly, at the normal working stage,
the air valve can discharge the small amount of gas gathered in the pipe timely; finally,
during the pump failure or maintenance stages, the air valve will replenish the gas into the
pipe to break the vacuum. According to the orifice size, displacement and work pressure,
air valve is divided into high pressure trace exhaust valve, low pressure air release valve
and combined air valve.
• Scour Valve:
These Valves are generally provided to drain out the pipeline. The exact location of Scour
valves is frequently influenced by opportunities to dispose off the water. Where the main
pipeline crosses a stream or drainage structures, there will usually be a low point in the line
but if the main pipeline goes under the stream or drain, it cannot be completely drained into
the channel. In such a situation it is better to locate a scour connection at the lowest point
that will drain by gravity and provide for pumping out the part below the drain pipeline.
• Control Valve:
573
A) Sliding Stem
• Globe valve
B) Rotary
• Butterfly valve
• Ball valve
C) Other
• Pinch valve
• Diaphragm valve
• Post-delivery testing of pipes

After delivery of pipes to worksite, additional test, if desired by Engineer-in-charge, shall
be conducted on random samples of pipes collected from site. These tests shall be as per
those given in forgoing paragraph.

• Work of PDN shall be inspected, tested and certified by PMC / TPI / QC. Modalities
of PMC / TPI / QC Inspection shall be separately decided and given by Engineer In-
charge.
• Project management consultants (PMC) should have approved laboratories
certification or collaboration with N.A.B.L. (National Accreditation Board for Testing
and Calibration Laboratories).
• Third party Inspection can be done form any one of the following services or from any
other mutually agreed agency.
1 Engineers India Limited, Mumbai.
2 R.I.T.E.S. (Rail India Technical Economics Services) Mumbai
3 S.G.S, Mumbai.
5 VJTI, Mumbai.
6 CWPRS (Central Water & Power Research Station), Pune.
intervals at which such testing is to be done etc. shall be as per the latest editions of
relevant IS Codes and determined by the Engineer In-charge. The day-to-day and
periodical tests to be carried out on materials mixes and placed concrete, mortar etc.
shall be specified by the Engineer In-charge from time to time and the Contractor
shall provide free of cost all facilities towards collections of samples etc. unless
otherwise specified. Labours for collecting samples and transportation of the samples
to quality control authorities for test shall be provided free of cost by the contractor.
Also electricity, fuel, water curing tank and stores etc shall be provided free of cost
by the contractors.
574
(b) The materials shall be tested in QC laboratory or at any other place directed by the
representatives shall, however, be given access to all operations and tests that may be
carried out as aforesaid so that he may satisfy himself regarding the procedure and
methods adopted. It shall then be the Contractor’s responsibility to produce on the
work, materials and finished item to the standard as determined by the laboratory tests
or to take follow up action to rectify the quality.
(d) The Contractor shall make suitable arrangements to see that one of his representatives
remains present at the time of taking samples and shall authenticate the facts. If the
Contractor, fails to keep his representative present at site at the time of taking samples
or fail to provide required labours and other equipment to collect the samples, the
same shall be taken by the Engineer In-charge, and the samples selected shall be
considered as authentic. The cost incurred by the Engineer-In-charge when the
Contractor fails to provide required men and materials for collecting samples and or
their transport shall be recovered from the Contractor.
• On award of contract, the Contractor will have to provide adequate quality assurance
setup including Quality Assurance Engineer backed with suitable laboratory
assistants, labours and well equipped laboratory for taking necessary field test
required as per specifications and as per instructions of Engineer in charge.
Quality Assurance.
Graduate with 2 Year experience in QA testing and
report generation work)
2 Laboratory Assistants(Twelfth Pass with Science
Two to Four
subject with 2 year experience in testing of
(As per work)
material)
(One for each L.A.)
• Following minimum equipments shall be available in the field laboratory setup by the
contractor.
1 Earth Work – Field density, Moisture Content,
Field testing Equipments Sieves for Sand & Metal.
the testing of construction materials, pipes are required as per the detailed
carried out at the laboratory, selected by the Engineer-in-Charge at Contractor’s cost.
The other tests of mortar, concrete, sand, coarse aggregates etc. shall be carried out in
575
field laboratory set up by the contractor in presence of quality control representative
at contractors cost. Contractor shall through this procedure assure the quality of work.
specification.
work.
• Pre delivery testing of pipes shall be carried out by the contractor in the presence of
representative of Engineer-In-charge /WRD/QC/TPI.Like
1. Dimension: Critical dimensions, External diameter, Wall thickness, Length of pipe,
ovality, deviation from straight line.
2. Tensile test
3. Brinell hardness test
4.Hydraulic test
Like Manufactures name or trademark, Grade of raw material , Pressure rating,
Nominal diameter, Lot/batch No. of manufacturer, BIS certification mark, Third Party
Certification mark for each lot , Name of Department/Project for which pipes are
manufactured. Any other important matter that the manufacturer or purchaser deems
fit to be inscribed etc.
• DI pipes are less susceptible to cracking or breaking or impact but precautions should
be taken to prevent damage to the protective coating.
• Pipes should be loaded in such a way that they are secured and that no movement
should take place on the vehicle during transit.
• The pipes should be loaded on vehicles in pyramid or straight sided formation. In case
of pyramid loading, the pipes in the bottom layer should be restrained by the use of
broad wooden wedges secured to the vehicle being loaded. The pyramid is to be
formed by resting pipes between the pairs of pieces in the preceding layer with the
sockets in layers reversed. Straight sided loading may be used with supports along the
sides of the vehicles. The use of straight sided loading is advantageous for utilizing
full capacity of the vehicle.
• Cranes should be preferred for off-loading. However, for pipes up to 400 mm nominal
bore, skid timbers and ropes may be used.
576
• When using mechanical handling equipment, it is necessary to employ sufficient
personnel to carry out the operation efficiently with safety. The pipes should be lifted
smoothly without any jerking motion and pipe movement should be controlled by the
use of guide ropes in order to prevent damage caused by pipes bumping together or
against surrounding objects.
• Where the crane operator does not have a clear view, he should be guided by the
personnel supervising the operation. The hooks should be of suitable shape to ensure
positive engagement when entered into the ends of the pipes and then should pass over
any protective packing fitted around the pipe ends.
• The use of slings passed around bundles of pipes is not recommended because bundles
become unstable as the sling is drawn tight or released. However, when it is necessary
to use the central slinging method for lifting single pipe, a broad webbing sling is
recommended which minimizes the risk of the pipe slipping.
• While Stacking of Pipe at Site the first layer of pipes should be laid on a firm
foundation consisting of solid timbers set level on the ground. Subsequent layers
should be placed according to the method of stacking adopted. Care should be taken
so that the pipes do not rest on their sockets. The height of any stack should not exceed
2 m.
• After delivery of pipes to worksite, additional test, if desired by Engineer-in-charge,
• For the desired quality of work. Whenever the testing of construction materials, pipes
are required as per the detailed specifications or otherwise required by the Engineer-
in-Charge, the same shall be carried out at the laboratory, selected by the Engineer-in-
Charge at Contractor’s cost.
• The net length of pipes as laid or fixed shall be measured in running meters correct to
directed by the Engineer-in-Charge.

The break up to payment for supplying, laying, jointing & hydraulic testing of pipe line
shall be as under:-
A) 80% of the payment will be released after supplying, lowering, laying, jointing and third
party inspection of pipes in one WUA area.
B) Balance 10% of the payment will be released after satisfactory hydraulic testing of pipeline
and backfilling of trenches.
respective WUAs.
577

A certificate regarding smooth working of pipe distribution network from the Chairman of
WUA shall be binding for annual release of this amount.
----------***----------
578
12.17 Lowering, laying and jointing in proper grade and alignment D.I. pipes
(Item No. LIPDN 26)

Lowering, laying and jointing in proper grade and alignment D.I. pipes with cost of
all jointing materials (rubber packing, nut bolts, etc.) including cost of conveyance from stores
to site of works, all labours involved, etc. complete. Only SBR rubber Gasket to be used as
per IS 5382 and IS 12820 (for all class of pipes)

testing at works and site of alignment D.I. pipes including cost of conveyance from stores to
site of works, all labours involved, etc. complete. Only SBR rubber Gasket to be used as per IS
5382 and IS 12820 (for all class of pipes)
12.17.3 Material Specification

The Contractor shall clear the entire area required for setting out. All tree stumps, roots,
brushwood, rubbish of all kinds, loose stones and all other objectionable materials shall be
removed by the Contractor. Buried irrigation pipeline, and other structure, if any, shall be
removed by the Contractor. The ownership of all the usable material, so removed from clearing
site and/or excavation shall rest with the Engineer In-charge. Useful material shall be stacked
as directed. The Contractor shall dispose-off all un-useful materials as directed by the Engineer
In-charge.
• Demarcation
All materials such as pegs, bamboo’s and strings and templates for marking out slopes, and
labour required for line out should be provided by the Contractor at his own cost. The centre
line of excavation shall be clearly marked by pegs or by stones at each chain or change of
direction or at shorter intervals on curves, in the beginning. The final line out will be done by
fixing reference stone at suitable distances on either side of the centre line, beyond the canal
edges so that they are not disturbed during the construction period. The position of these stones
will be marked on the cross section.
Contractor shall provide and maintain the quarry roads and temporary roads required for
construction activity at his own cost.
(a) Benchmarks fixed by the Survey of India and temporary benchmarks established by the
Engineer In-charge in vicinity of PDN work will serve as control points for these works. The
Contractor shall establish sufficient number of reference benchmarks for facilitating setting out
of work and taking levels for the purpose of measurements.
(b) Before starting any work, the Contractor shall erect reference benchmarks, reference lines and
check profiles at convenient locations approved by the Engineer In-Charge. The benchmark
concrete block shall be 200mm x200mm x600mm with 400mm embedded in the firm ground
and 200 mm projecting above ground. The word ‘BM’ showing value of R.L. in ‘m’ shall be
conspicuously carved and painted on the benchmark.
579
(c) The check profile shall be located 30m apart or closer as directed by the Engineer In-Charge
so as to ensure execution of all slopes, steps and elevations to the profile or profiles indicated
in the approved drawings. All important levels and all control points with respect to
benchmarks and reference lines shall be fixed and correlated by the Contractor. The
Contractor is fully responsible for maintaining all setting out work & Benchmark established
by Engineer-In-charge.
(d) All materials, labour and equipment (theodolites, levels, distometre, etc.) for setting out works
including construction of benchmarks in concrete, reference lines, check profiles and surveys
as may be required at the various stages of construction shall be supplied by the Contractor
at his cost. For this following numbers of minimum equipments shall be provided and
maintained in good working condition by the Contractor.
2. Theodolites(Accuracy1second) 1No.
3. Levels 2Nos.
4. Staves 4Nos.
5. Tapes, chains, ranging rods etc. As required
All equipments shall be of standard and approved make and precision, and shall be made
available in advance of starting of the work. All equipment shall be maintained, repaired and
got tested and certified as and when required forints accuracy from the standard test houses
or from the manufactures and to the satisfaction of the Engineer-In-Charge.

• Excavation of pipe trenches shall be carried out as per excavation line shown in the drawing
or as directed by Engineer In-charge. Contractor must assume all responsibility for deductions
and conclusion made by him as to the nature of the materials to be excavated and the
difficulties of making and maintaining the required excavation. The trench width at bottom
shall be 300 mm more than 1.5 times outside pipe diameter. In any case trench width shall not
be less than 500 mm.
• The usable excavated material available from the excavated trenches (PDN) shall be used in
backfilling. If such usable material is in excess of the requirement of backfilling, the same
shall be deposited in the spoils as and where directed by the Engineer In-charge. Un-useful
material from excavation shall be deposited in spoils as and where directed by Engineer-In-
charge.
• Surface or sub-soil water met with during trench excavation (PDN) and structure excavation
shall be diverted to nearby drain/nalla by cutting an open channel from trench. When the
drain/nalla bed is higher than the sub-soil water level met with, the bailing out by suitable
means of pumping shall be resorted to for dewatering sub-soil water below the drain/nalla bed
level. No distinction shall be made as to whether the material being excavated is dry, moist,
wet or slushy. The Contractor shall have to excavate the PDN pipe trench and structure in
under water level conditions also i.e. under wet/slushy condition after providing sufficient
arrangement of dewatering. The material excavated under water level condition which
requires intermediate stacking for drying shall have to be re-handled. No extra payment for
efforts for drying out of soil, re-handling of dry soil, etc. shall be given. No payment for extra
efforts for excavation under this condition shall be made.
580
• Over excavation performed by the Contractor for any purpose or reason, except for additional
excavation as may be directed by the Engineer-In-Charge, shall be rectified at the cost of the
Contractor. Filling and compaction for such over excavation using the material as directed by
the Engineer-In- Charge shall also be at the cost of the Contractor.
• In the PDN and structure section where expansive type of the soil such as CH type of soil is
encountered and over which PDN cannot be directly laid, the PDN trench and structure shall
be over excavated to the extent as directed by the Engineer In Charge and such over excavated
section shall be filled with suitable murum type soil to be placed in uniformly compacted
layers as directed by the Engineer In Charge. The over excavation made in such strata, filling
by suitable soil, and watering and compacting such soil will be paid separately under relevant
items. Above provision for over excavating and filling with suitable murum type or good soil
available material shall be applicable in case such treatment is found essential.
• Laying of Pipes
While laying of DI pipes, all precautions mentioned in IS 12288 shall be taken
• Pipes should be lowered into the trench with tackle suitable for the weight of pipes.
• For smaller sizes, up to 250 mm nominal bore, the pipe may be lowered by the use of ropes
but for heavier pipes, either a well-designed set of shear legs or mobile crane should be used.
• If sheathed pipes are being laid, suitable wide slings or scissor dogs should be used.
• All construction debris should be cleared from the inside of the pipe either before or just after
a joint is made. This is done by passing a pull-through in the pipe, or by hand, depending on
the size of the pipe.
• When laying is not in progress, a temporary end closure should be securely fitted to the open
end of the pipeline. This may make the pipe buoyant in the event of the trench becoming
flooded, in which case the pipes should be held down either by partial re-filling of the trench
or by temporary strutting.
• On gradients of 1:15 or steeper, precautions should be taken to ensure that the spigot of the
pipe being laid does not move into or out of the socket of the laid pipe during the jointing
operations. As soon as the joint assembly has been completed, the pipe should be held firmly
in position while the trench is backfilled over the barrel of the pipe. The backfill should be
well compacted.
• The cutting of pipe for inserting valves, fittings, etc. shall be done in a neat and workman like
manner without damage to the pipe or lining so as to leave a smooth end at right angles to the
axis of the pipe. Cutting of pipes can be done either by hand/power operated hacksaw or
manually operated wheel cutter or by pipe cutting machines.
• The burr left after cutting should be trimmed off by light grinding or by filling.
• At joints, bends and valves, precautions should be taken to provide sufficient overlap of the
wrapping sleeve so that no pipe line is exposed to the aggressive soil.
• All pipelines having unanchored flexible joints require anchorage at changes of direction and
at dead ends to resist the thrusts developed by internal pressure.
• Each pipe shall be checked for any damage before laying and only the pipe which are approved
by the Engineer shall be laid.
• Where pipes are to be bedded directly on the bottom of the trench, it should be trimmed &
leveled to permit even bedding of the pipe line. However while laying in rocky areas, 150 mm
compacted fine sand bedding under and around pipe needs to be provided.
• Jointing of Pipes-
Jointing of pipes shall be done as per procedure laid down in IS 12288. The joints are mainly
of two type viz. flexible joints & flanged joints.
581
Flexible Joint-
• The spigot and socket flexible joint should be designed to permit angular deflection in
direction and axial movement to compensate for ground movement and thermal expansion
and contraction. They incorporate gasket of elastomeric materials and the joints may be of the
simple push-on-type or the type where the seal is effected by the compression of a rubber
gasket between a seating ring on the inside of the socket & external surface of the spigot.
• Flexible joints are required to be externally anchored at all changes in direction such as at
bends, at blank end to resist the thrust created by internal pressure and to prevent the
withdrawal of spigots.
Flanged Joint-
• Flanged joints are made on pipes having a machined flange at each end of the pipe. The seal
is usually affected by means of a flat rubber gasket compressed between two flanges by means
of bolts which also serve to connect the pipe rigidly. Gaskets of other materials, both metallic
and non-metallic, are used for special applications.
• In case of ductile iron pipes with screwed on flanges or welded flanges, the flanges shall be at
right angle to the axis of the pipe and shall be machined on face. The bolt holes shall be either
cored or drilled.
582
• Jointing Procedure-
• Procedure for jointing will vary according to the type of joint being used. Basic requirements
for all types are:
a) Cleanliness of all parts,
b) Correct location of components,
c) Centralization of Spigot within socket, and
d) Strict compliance with manufacturer's jointing instructions.
• The inside of sockets and the outside of spigots should be cleaned and wire brushed for a
distance of 150 to 225 mm.
• Glands & gaskets should be wiped clean and inspected for damage.
• When the pipeline is likely to be subjected to movement due to subsidence or temperature
variations, the use of flexible joints is recommended. A gap should be left between the end of
the spigot and the back of socket to accommodate such movement.
(a) The type of material used for backfilling and the manner of depositing the material, shall be
subject to approval by the Engineer-in-Charge.
(b)The backfill material shall be placed to the line and grades as shown on drawings or as
prescribed in this paragraph or as directed by the Engineer-in-Charge.
(c) The backfill material shall be placed carefully and spread in uniform layers of not more than
15cm thickness, with the first layer watered and compacted by stamping or by mechanical
means. The backfill shall be brought up as uniformly as practicable on both sides of pipe to
prevent unequal loading.
(d)Only soft earth and gravel of good quality free from boulder, roots, vegetable matters etc. shall
be used for refilling of trench upto 300mm above the top of the pipe. If sufficient quantity of
suitable (Sharp edge stone free) excavated earth is not available, the trench shall be filled by
borrowed gravel material up to 300 mm above top of pipeline. Remaining trench can be filled
with available material.
(e) When compacting the soil against steep rock, abutment walls of concrete structures, rollers
shall not be used close to structures as structural damage is very likely more particularly when
structures have not been fully cured. The size and weight of equipment will depend on nature
of material, the height and load assumed in design of structure. The backfill close to the
structure up to the rolled layer shall be compacted in suitable uniform layers, using pneumatic
/ hand tampers as appropriate for dry density at average bulk density (+/- 10%). The moisture
content of the earth fill placed against the rock or the structure shall be on higher/lower side
of OMC by about 2% or so, to allow it to be compacted. Profuse watering shall be done to
pervious materials (sand) before compaction as per instruction of the Engineer-in-Charge.
Compaction at junction of earthwork and backfill around the structure shall be carried out
with special care.

• The contractor shall establish the sufficient number of reference blocks on the alignment
of PDN preferably at the interval of 30m or as suitable on the field boundaries so as they
will not be disturbed during the agricultural activities of the farmers.
• The marking shall be constructed in prefabricated concrete block of size (15x15x45) CM
embedded in concrete block of size (30x30x30) CM. The base of this block shall be buried
in ground projecting only 15cm above the ground and the base concrete block.
• These blocks shall be able to locate the pipeline as and where it is laid all over the work. The
contractor shall mark each block with specific distinct identification mark.
583
representative, representative of WUA, concern farmers sharing the boundaries, TPI, any
other stake holders in the command.
• Contractor shall maintain these blocks in proper order during operation & maintenance
period of the contract. Any damage done to these blocks for the reasons whatsoever shall be
made good at the cost of contractor.
• The contractor shall submit the location of such blocks with specific identification marks
with schedule on a special command area map.
• The map of marking of the block shall be handed over to WUA while handing over the
command area.
• The Geo-tagging map showing Latitude and Longitude value of each apex of laid pipeline
shall be submitted to Department and WUA for future reference.
• The contract shall fix information boards of 1.2 m x 0.9 m size at various location as directed
by Engineer-in-charge. On these boards, salient features of the work (e.g. Pipe diameter, pipe
type, discharge, any other specific details suggested by Engineer-In-Charge) shall be written.

• Work of PDN shall be inspected, tested and certified by PMC / TPI / QC. Modalities of PMC
/ TPI / QC Inspection shall be separately decided and given by Engineer In-charge.
• Project management consultants (PMC) should have approved laboratories certification or
collaboration with N.A.B.L. (National Accreditation Board for Testing and Calibration
Laboratories)
• Third party Inspection can be done form any one of the following services or from any other
mutually agreed agency.
2 R.I.T.E.S. (Rail India Technical Economics Services) Mumbai.
3 S.G.S, Mumbai.
4 Vishveshvaraya National Institute of Technology, Nagpur.
5 VJTI, Mumbai.
(a) All materials before being utilized in works shall be inspected and tested, by the Engineer
In-charge or his representative/QC. The nature of testing and periodical intervals at which
such testing is to be done etc. shall be as per the latest editions of relevant IS Codes and
determined by the Engineer In-charge. The day-to-day and periodical tests to be carried out
on materials mixes and placed concrete, mortar etc. shall be specified by the Engineer In-
charge from time to time and the Contractor shall provide free of cost all facilities towards
collections of samples etc. unless otherwise specified. Labours for collecting samples and
transportation of the samples to quality control authorities for test shall be provided free of
cost by the contractor. Also electricity, fuel, water curing tank and stores etc. shall be
(b) The materials shall be tested in QC laboratory or at any other place directed by the Engineer
In-charge. The Contractor shall obtain the test results from the concern authority and the
results given by such authorities shall be considered to determine whether all materials,
workmanship are of respective standard described in contract and in accordance with the
instructions of the Engineer In-charge. The Contractor’s representatives shall, however, be
given access to all operations and tests that may be carried out as aforesaid so that he may
satisfy himself regarding the procedure and methods adopted. It shall then be the
Contractor’s responsibility to produce on the work, materials and finished item to the
584
standard as determined by the laboratory tests or to take follow up action to rectify the
quality.
(c) Testing charges for testing of Cement, TMT bars, all types of pipes and specials including
cost of samples and its collection shall be borne by the Contractor.
Contractor, fails to keep his representative present at site at the time of taking samples or fail
to provide required labours and other equipment to collect the samples, the same shall be
taken by the Engineer In-charge, and the samples selected shall be considered as authentic.
The cost incurred by the Engineer-In-charge when the Contractor fails to provide required
men and materials for collecting samples and or their transport shall be recovered from the
Contractor.

• On award of contract, the Contractor will have to provide adequate quality assurance setup
including Quality Assurance Engineer backed with suitable laboratory assistants, labours
and well equipped laboratory for taking necessary field test required as per specifications
and as per instructions of Engineer in charge.
• Following minimum persons shall be employed by the contractor at work site for Quality
Assurance.

2 Laboratory Assistants(Twevlth Pass with Science
Two to Four
(As per work)
material)
(One for each L.A.)
contractor.
Field testing Equipments for Sand & Metal.
• It is the responsibility of the contractor to assure the desired quality of work. Whenever the
testing of construction materials, pipes are required as per the detailed specifications or
otherwise required by the Engineer-in-Charge, the same shall be carried out at the laboratory,
selected by the Engineer-in-Charge at Contractor’s cost. The other tests of mortar, concrete,
sand, coarse aggregates etc. shall be carried out in field laboratory setup by the contractor in
presence of quality control representative at contractors cost. Contractor shall through this
procedure assure the quality of work.
• The materials, mixes and any other arrangements, including labours, shall be supplied by the
contractor. The samples for testing shall be taken in the presence of Engineer-in-Charge or his
representative /QC present on site. The contractor or his authorized representative shall have
a free access in these laboratories, to get himself satisfied about procedures of testing etc. Even
585
if the contractor or his representative fails to remain present while collecting samples or
testing, the results will be considered as authentic and binding on the contractor.
• Contractor shall provide all test reports of material used in the work as desired from the NABL
(National Accreditation Board for Testing & Calibration Laboratories) approved laboratories
and from Quality Control, MERI laboratories of the WRD. Contractor shall provide periodical
quality assurance report (Weekly/fortnightly/monthly) to Engineer in Charge along with
proofs in support of quality of material brought for the work, the process/ execution of work
is as per specification.
• Contractor shall submit the account of all materials brought for the work, which are necessary
for execution of work and any other data necessary to assess the quality of work.
laboratory with required equipments will be deployed by the Engineer in charge and the
charges for the same will be recovered from the contractor.

• The Contractor shall clear the entire area required for setting out. All tree stumps, roots,
removed by the Contractor.
• All materials such as pegs, bamboo’s and strings and templates for marking out slopes, and
labour required for lineout should be provided by the Contractor at his own cost.
• The center line of excavation shall be clearly marked by pegs or by stones at each chain or
change of direction or at shorter intervals on curves, in the beginning. The final lineout will
be done by fixing references to neat suitable distances on either side of the center line, beyond
the canal edges so that they are not disturbed during the construction period.
• Prior permission of other department like P.W.D., H.P.C.L, M.J.P. shall be taken if the
alignment of pipe line crosses railway line, roads, gas pipe lines etc.
• Benchmarks fixed by the Survey of India and temporary benchmarks established by the
Engineer In-charge in vicinity of PDN work will serve as control points.
• Before starting any work, the Contractor shall erect reference benchmarks, reference lines and
check profiles at convenient locations approved by the Engineer In-Charge.
• All materials, labour and equipments (theodolites, levels, distometre, etc.) for setting out
works including construction of benchmarks in concrete, reference lines, check profiles and
surveys as may be required at the various stages of construction shall be supplied by the
Contractor at his cost.
• Excavation of pipe trenches shall be carried out as per excavation line shown in the drawing
or as directed by Engineer In-charge.
• The usable excavated material available from the excavated trenches(PDN) shall be used in
shall be deposited in the spoils as and where directed by the Engineer In-charge.
• In the PDN and structure section where expansive type of the soil such as CH type of soil is
be over-excavated to the extent as directed by the Engineer In-Charge and such over-
excavated section shall be filled with suitable murum type soil to be placed in uniformly
compacted layers as directed by the Engineer In-Charge. The over-excavation made in such
strata, filling by suitable soil, and watering and compacting such soil will be paid separately
under relevant items. Above provision for over-excavating and filling with suitable murum
type or good soil available material shall be applicable in case such treatment is found
essential.
• Before the pipes are lowered and laid in position the contractor shall see that the invert at the
support is correct and pipe is brought to uniform grade and level. This should be checked with
the help of dumpy level and should be got approved in advance from Engineer-in-charge.
• While laying of DI pipes, all precautions mentioned in IS 12288 shall be taken.
586
• Valve like Air valve, Scour Valve and Control valve shall be constructed as per drawings.
• Pipes should be lowered into the trench with tackle suitable for the weight of pipes.
• For smaller sizes, up to 250 mm nominal bore, the pipe may be lowered by the use of ropes
but for heavier pipes, either a well-designed set of shear legs or mobile crane should be used.
• If sheathed pipes are being laid, suitable wide slings or scissor dogs should be used.
• All construction debris should be cleared from the inside of the pipe either before or just after
a joint is made. This is done by passing a pull-through in the pipe, or by hand, depending on
the size of the pipe.
• When laying is not in progress, a temporary end closure should be securely fitted to the open
end of the pipeline. This may make the pipe buoyant in the event of the trench becoming
flooded, in which case the pipes should be held down either by partial re-filling of the trench
or by temporary strutting.
• On gradients of 1:15 or steeper, precautions should be taken to ensure that the spigot of the
pipe being laid does not move into or out of the socket of the laid pipe during the jointing
operations. As soon as the joint assembly has been completed, the pipe should be held firmly
in position while the trench is backfilled over the barrel of the pipe. The backfill should be
well compacted.
• The cutting of pipe for inserting valves, fittings, etc. shall be done in a neat and workman like
manner without damage to the pipe or lining so as to leave a smooth end at right angles to the
axis of the pipe. Cutting of pipes can be done either by hand/power operated hacksaw or
manually operated wheel cutter or by pipe cutting machines.
• The burr left after cutting should be trimmed off by light grinding or by filling.
• At joints, bends and valves, precautions should be taken to provide sufficient overlap of the
wrapping sleeve so that no pipe line is exposed to the aggressive soil.
• All pipelines having unanchored flexible joints require anchorage at changes of direction and
at dead ends to resist the thrusts developed by internal pressure.
• Each pipe shall be checked for any damage before laying and only the pipe which are approved
by the Engineer shall be laid.
• Where pipes are to be bedded directly on the bottom of the trench, it should be trimmed &
leveled to permit even bedding of the pipe line. However while laying in rocky areas, 150 mm
compacted fine sand bedding under and around pipe needs to be provided.
• Jointing of pipes should be done as per Procedure mentioned in IS 7634.Thecommonly used
joints are as follows:
a) Fusion welding:
1) Butt fusion welding;
2) Socket fusion welding;
3) Electro fusion welding;
b) Insert type joints;
c) Compression fittings/push fit joints;
d) Flanged joints
e) Spigot and socket joints.
• The detailed Jointing Procedure of above mentioning various joints shall be as per IS 7634
(Part-II)
• The type of material used for backfilling and the manner of depositing the material, shall be
subject to approval by the Engineer-in-Charge.
• The backfill material shall be placed to the line and grades as shown on drawings or as
• The backfill material shall be placed carefully and spread in uniform layers of not more than
587
• Only soft earth and gravel of good quality free from boulder, roots, vegetable matters etc.
shall be used for refilling of trench up to 300mm above the top of the pipe. If sufficient
quantity of suitable (Sharp edge stone free) excavated earth is not available, the trench shall
be filled by borrowed gravel material up to 300 mm above top of pipeline. Remaining trench
can be filled with available material.
• When compacting the soil against steep rock, abutment walls of concrete structures, rollers
shall not be used close to structures as structural damage is very likely more particularly when
structures have not been fully cured. The size and weight of equipment will depend on nature
of material, the height and load assumed in design of structure. The backfill close to the
structure up to the rolled layer shall be compacted in suitable uniform layers, using pneumatic
/ hand tampers as appropriate for dry density at average bulk density (+/- 10%). The moisture
content of the earth fill placed against the rock or the structure shall be on higher/lower side
of OMC by about 2% or so, to allow it to be compacted. Profuse watering shall be done to
pervious materials (sand) before compaction as per instruction of the Engineer-in-Charge.
Compaction at junction of earthwork and backfill around the structure shall be carried out
with special care.
• The trench shall be refilled so as to built-up the original ground level.
• The backfill material shall be placed carefully and spread in uniform layers of not more than
• Only soft earth and gravel of good quality free from boulder, roots, vegetable matters etc.
shall be used for refilling trench up to 300mm above top of pipe. If sufficient quantity of
suitable (Sharp edge stone free) excavated earth is not available, the trench shall be filled by
borrowed gravel material up to 300 mm above top of pipeline. Remaining trench can be filled
with available material.
• The moisture content of the earth fill placed against the rock or the structure shall be on
higher/lower side of OMC by about 2% or so, to allow it to be compacted. Profuse watering
shall be done to pervious materials (sand) before compaction as per instruction of the
Engineer-in-Charge.
• Compaction at junction of earthwork and backfill around the structure shall be carried out
with special care.
• The contractor shall establish the sufficient number of reference blocks for permanent
marking on the alignment of PDN preferably at the interval of 30m or as suitable on the field
boundaries so as they will not be disturbed during the agricultural activities of the farmers.
• For the desired quality of work. Whenever the testing of construction materials, pipes are
required as per the detailed specifications or otherwise required by the Engineer-in-Charge,
the same shall be carried out at the laboratory, selected by the Engineer-in-Charge at
Contractor’s cost.
The net length of pipes as laid or fixed shall be measured in running meters correct to a cm.
Specials shall be excluded and measured in running meters or numbers as specified by
Engineer-in-charge and paid for separately under the relevant item. The portion of the pipe
overlapped at the joints shall not be included in the length of pipe work. Excavation, refilling,
anchor blocks, thrust blocks wherever required shall be measured and paid for separately
under relevant items of work.
588
shall be as under:-
respective WUAs.
A certificate regarding smooth working of pipe distribution network from the
Chairman of WUA shall be binding for annual release of this amount.
----------***----------
589
12.18 Providing and supplying ISI standard D. I. specials (Item No. Item No.
LIPDN 27)
Providing and supplying ISI standard D. I. specials & fitting with sealing rubber gasket
of S.B.R, complete with cast iron follower gland and M. S. nut bolts coated or otherwise
protected from rusting and suitable for D.I. pipes including cost of labour, materials, and
transportation to stores / site, loading and unloading excluding GST levied by GOI & GOM
in all respect, as per IS-9523. For all types of specials, bends, tees etc. Complete.

This specification covers the requirements for providing and supplying Providing and
supplying ISI standard D. I. specials & fitting with sealing rubber gasket of S.B.R, complete
with cast iron follower gland and M. S. nut bolts coated or otherwise protected from rusting
and suitable for D.I. pipes including cost of labour, materials, and transportation to stores /
site, loading and unloading excluding GST levied by GOI & GOM in all respect, as per IS-
9523. For all types of specials, bends, tees etc. Complete.

• Introduction
Ductile iron (DI) pipes are manufactured from ductile iron. Ductile iron is a type of
iron in which graphite is present primarily in spherical or nodular form.
The Contractor shall provide on-site training on DI pipe laying, jointing, testing and
should provide technical Manual on DI pipes including precautions to be taken during
The manufacturing, testing, supplying, laying, jointing and testing at work sites of DI
PSC Pipes form part of these Specifications.
IS 8329 Centrifugally cast(spun) ductile iron pressure pipes for water, gas
and sewage
IS 9523 Ductile iron fittings for pressure pipes for water, gas and sewage
IS 12288 Code of practice for use and laying of Ductile Iron pipes
IS 11606 Methods for sampling of Cast Iron pipes and fittings
IS 5382 Rubber sealing rings for gas mains, water mains and sewers
IS 638 Specification for Sheet Rubber Jointing and Rubber Insertion Jointing
IS1608 Mechanical testing of metals -tensile testing
IS1500 Methods for Brunel hardness test for metallic materials
• Raw Materials
Raw material used in manufacturing of pipes (with or without coating) is ductile iron,
cement, sand, water, zinc, bitumen, polyethylene and rubber gasket.
Ductile Iron: The general requirements relating to the supply of DI metal used in pipe
manufacturing shall be as per IS 1387 and IS 8329. The metal used for the manufacture
of pipes shall be of good quality commensurate with the mechanical requirements
590
Cement: The cement used for the pipe lining shall conform to the existing
standards of cement. Following types of cement can be used for lining.
b) Ordinary Portland cement conforming to IS 8112 or IS 415.
c) Sulphate resisting Portland cement conforming to IS 12330 or IS 6909.
d) High alumina cements conforming to IS 6542.
Sand: The sand used shall have a controlled granulo metric distribution from
fine to coarser elements. It shall be clean and shall be composed of inert, hard,
strong & stable granular particles. The gradation of sand shall be as specified in
IS 8329.
Water: The water used for the preparation of mortar shall not contain
substances deleterious to the mortar.
Zinc: Zinc used for coating purpose is metallic zinc with content of at least 99
% by mass.
Bitumen: Bitumen used for coating purpose shall be smooth, tenacious and
hard as specified in IS 8329.
Polyethylene: The density of polyethylene shall be between 910 to 930 kg/m³.
Rubber gasket: Rubber gaskets used with push-on joints or mechanical shall
conform to IS5382, whereas rubber gaskets for use with flanged joints shall
conform to IS638.
• The metal used for the manufacture of pipes shall be of good quality,
commensurate with the mechanical requirements laid down of IS 8329.
• The pipes shall be stripped with all precaution to avoid warping or shrinkage
defects, detrimental to their good quality. The pipes shall be sound and free
from surface or other defects.
• Pipes centrifugally cast shall be heat-treated in order to achieve the necessary
mechanical properties and to relieve casting stresses caused due to the method
of manufacture and repair work.
• If necessary, the pipes may be subjected to reheat treatment to ensure that
Brinell hardness does not exceed the specified value and the other mechanical
properties specified in IS8329 are achieved.
The manufacturing process flow of DI Pipe is as given the below.

Molten Iron
Induction Furnace
Spheroidization
Core Making
Centrifugal Casting
Annealing
Zinc Spraying
Grounding & Grinding
Hydraulic Testing
Cement Lining
Cultivating
Bitumen Coating
Packing
591
• Pipes have been classified as K7,K8,K9, K10, K12,….depending on service
conditions and manufacturing processes
• The class designation shall comprise of
(a) prefix K
(b) A whole number used for thickness. class designation
• The wall thickness of pipe ‘e’ in mm shall be calculated as function of the
nominal diameter by the following equation with minimum of 5mm for K=7,
6mm for k=8 & 7mm for K=12.
e=K(0.5+0.001DN)
Where,
e=wall thickness in mm
DN=the nominal diameter, & K=the whole number coefficient.
• The value of K will depend on following service conditions.
Service conditions
Nominal dia. Water Sewers Gas main
Main
80-300 K9-K12 K7-K12 K9-K12
350-600 K8-K10 K7-K10 K9-K10
700-2000 K7-K10 K7-K10 K9-K10
• For screwed or welded on flange pipes the minimum classes as per working
pressure criteria are given below.
Coating: DI pipes shall normally be coated externally and internally.

External protection: Depending upon external condition of use, the external
protections can be of following three types as specified in IS 8329.
a) Zinc coating:
592
• The pipe surface shall be dry and free from rust or any non-adhering particles
or foreign matters such as oil or grease. Metallic zinc shall be applied on to the
oxide external surface of the pipe.
• The coating materials are metallic zinc with content of at least 99% by mass.
• The metallic zinc coating shall be applied by as spraying process, in which
metallic zinc material is heated to molten state & projected in small droplets by
spray guns onto surface. The zinc rich paint coating shall be applied by a
spraying or a brush process onto the pipe surface in case of repairs only.
• The metallic zinc coating shall cover the outside diameter of the pipe and shall
be free from such defects as bare patches or lack of adhesion.
• Damaged areas of zinc coating caused by handling are acceptable provided that
the damage is less than 5cm2/m2 of coated surface & provided that the minor
dimensions of the damaged area do not exceed 5mm.
• The average mass of zinc coating shall be not less that 130g/m 2 with local
minimum of 110gm/m2
• After metallic zinc coating or zinc paint coating, the pipe shall be given a
finishing layer of bituminous paint or synthetic resin compatible with the zinc
coating.
• Applications of the finishing layer may be done by any proven process such as
spraying or brush coating at the manufacturer’s choice. It shall uniformly cover
zinc coating and be free from bare patches or lack of adhesion.
• The mean dry film thickness of the finishing layer shall not be less than 70µm.
with nowhere less than 50µm.
b) Bituminous coating:
• Coating shall not be applied to any pipe unless its surfaces are clean, dry & free
from rust.
• The mean thickness of coating shall be not less than 70µm & the local minimum
thickness shall be not less than 50µm.
• Where the coating material has a bitumen base, it shall be smooth & tenacious
and hard enough not to flow, when expose to temperature of 650 c but not so
brittle at a temperature of 00C as to chip off when scribed with a penknife.
C) External sleeving:
• The polyethylene sleeves may be supplied, for encasement of the pipes at site,
along with the pipes if ordered by the purchaser. This encasement shall be so
designed that prevent contact between pipe and surroundings backfill and
bedding material.
• The material used for making the film is polyethylene or a mixture of
polyethylene and /or ethylene and olefin copolymers. Its density shall be
between 910 & 930 kg/m3.
• If protection against ultra violet rays is required, the material shall be stabilized
by the additions of an appropriate product, if carbon black is used for this
purpose the addition shall be in the range of 2 to 3 % by mass.
Internal lining: Depending upon the internal conditions of use, the internal lining
can be of following two types as specified in IS 8329.
a) Cement mortar lining: The cement used for the lining shall be either ordinary
Portland cement or sulphate resisting portland cement or high alumina cement.
• The mortar of the lining shall be composed of cement, sand & water. Additives,
which shall be specified, may be used, provided that they do not prejudice the
quality of the coating & that of the transported water. The mortar shall contain by
mass at least 1 part of cement to 3.5 parts of sand.
• All foreign bodies, loose scale or any other material which could be detrimental
to good contact between the metal & the lining shall be removed from the surface
593
to which the lining is to be applied. The inner surface of pipe shall also be free of
any metal projections likely to protrude beyond 50% of thickness of the lining.
• The cement mortar lining at works is applied by a centrifugal spinning process or
a centrifuged sprinkler or combination of both methods.
• Lining thickness varies from 3mm to 9mm depending on pipe thickness as
• The surface of the cement mortar lining shall be uniformly smooth. Only isolated
grains of the sand are allowed to appear on the surface of the lining.
• When specified, the cement lining shall be given a seal coat of bituminous
material or any other epoxy base material compatible with cement mortar lining.
The purpose of the seal coat is to minimize lime, leaching of the cement mortar
as well as to restrict the unwanted rise in pH value of the transmitted water.
b) Bituminous paint: The specification for this shall be as given in above sub para.
• Valves
For PDN work, various Valves as mentioned below are required to be provided
on pipeline at various locations.
• Air Valve:
The effect of air valve in the long-distance water pipelines are in the following
three areas: firstly, in the waterfilled stage of the pipeline, filled with water by
a certain velocity, the air valve can discharge the remained gas in the pipe;
secondly, at the normal working stage, the air valve can discharge the small
amount of gas gathered in the pipe timely; finally, during the pump failure or
maintenance stages, the air valve will replenish the gas into the pipe to break
the vacuum. According to the orifice size, displacement and work pressure, air
valve is divided into high pressure trace exhaust valve, low pressure air release
valve and combined air valve.
• Scour Valve:
of Scour valves is frequently influenced by opportunities to dispose off the
water. Where the main pipeline crosses a stream or drainage structures, there
will usually be a low point in the line but if the main pipeline goes under the
stream or drain, it cannot be completely drained into the channel. In such a
situation it is better to locate a scour connection at the lowest point that will
drain by gravity and provide for pumping out the part below the drain pipeline.
• Control Valve:
A control valve is a valve used to control fluid flow by varying the size of the
flow passage as directed by a signal from a controller. This enables the direct
control of flow rate and the consequential control of process quantities such
A) Sliding Stem
• Globe valve
B) Rotary
• Butterfly valve
• Ball valve
C) Other
594
• Pinch valve
• Diaphragm valve

• Third party Inspection can be done form any one of the following services or
from any other mutually agreed agency.
3 S.G.S, Mumbai.
5 VJTI, Mumbai.
curing tank and stores etc. shall be provided free of cost by the contractors.
(b) The materials shall be tested in QC laboratory or at any other place directed by
(d) The Contractor shall make suitable arrangements to see that one of his
595
laboratory assistants, labours and well equipped laboratory for taking
necessary field test required as per specifications and as per instructions of
Engineer in charge.
• Following minimum persons shall be employed by the contractor at work site
for Quality Assurance.
2 Laboratory Assistants(Twelvth Pass with Science
Two to Four
(As per work)
material)
(One for each L.A.)
• Following minimum equipments shall be available in the field laboratory setup

by the contractor.

detailed specifications or otherwise required by the Engineer-in-Charge, the
same shall be carried out at the laboratory, selected by the Engineer-in-Charge
at Contractor’s cost. The other tests of mortar, concrete, sand, coarse
aggregates etc. shall be carried out in field laboratory set up by the contractor
in presence of quality control representative at contractors cost. Contractor
shall through this procedure assure the quality of work.
supplied by the contractor. The samples for testing shall be taken in the
presence of Engineer-in-Charge or his representative /QC present on site. The
contractor or his authorized representative shall have a free access in these
laboratories, to get himself satisfied about procedures of testing etc. Even if the
contractor or his representative fails to remain present while collecting samples
or testing, the results will be considered as authentic and binding on the
contractor.
• Contractor shall provide all test reports of material used in the work as desired
from the NABL (National Accreditation Board for Testing & Calibration
Laboratories) approved laboratories and from Quality Control, MERI
laboratories of the WRD. Contractor shall provide periodical quality assurance
report (Weekly/fortnightly/monthly) to Engineer in Charge along with proofs
596
in support of quality of material brought for the work, the process/ execution
of work is as per specification.
• Contractor shall submit the account of all materials brought for the work, which
are necessary for execution of work and any other data necessary to assess the
quality of work.
• If he fails to fulfill the above requirement, the required manpower for testing
and field laboratory with required equipments will be deployed by the Engineer
in charge and the charges for the same will be recovered from the contractor.

• All fittings/specials shall be fabricated or moulded at factory only. No
fabrication or moulding will be allowed at site, unless specifically permitted by
Engineer-in-Charge, the same shall be carried out at the laboratory, selected by
the Engineer-in-Charge at Contractor’s cost.
The Specials of pipes as laid or fixed shall be measured in Kg correct to a gm as

The break up to payment for supplying, laying, jointing & hydraulic testing of pipe
line shall be as under:-
third party inspection of pipes in one WUA area.
maintenance and operation for a period of five years after commissioning of work
of respective WUAs.
1)After Successful Operation and Maintenance for First year-2%

2)After Successful Operation and Maintenance for Second year-2%
3)After Successful Operation and Maintenance for Third year-2%
4)After Successful Operation and Maintenance for Fourth year-2%
5)After Successful Operation and Maintenance for Fifth year-2%
----------***----------
597
12.19 Hydraulic testing of D.I. pipe line to specified pressure
(Item No. LIPDN 28)
Hydraulic testing of D.I. pipe line to specified pressure including cost of all
materials and labour and water for testing for specified length including cutting, placing
end cap making arrangement for filling safe water using reciprocating type pumps
which should be able to provide specified test pressure gauges and other necessary
equipments, labour, operation charges, etc. required for testing. The rate under this item
shall also include cost of retesting, if necessary and reinstating to original position using
water supplied by the contractor.

This specification covers the requirements for hydraulic testing at works and site of D.I.
pipe line to specified pressure including cost of all materials and labour and water for
testing for specified length including cutting, placing end cap making arrangement for
filling safe water using reciprocating type pumps which should be able to provide
specified test pressure gauges and other necessary equipments, labour, operation
charges, etc. required for testing. The rate under this item shall also include cost of
retesting, if necessary and reinstating to original position using water supplied by the
contractor.
12.19.3 Field Testing of Pipeline System

• General
• All pipelines should be tested before being brought into service. The test
should be a hydrostatic test performed by filling the pipeline with water and
raising the pressure to the selected test pressure and maintaining this for a
sufficient period to allow for absorption of water by the pipe material.
• After a new pipeline is laid and jointed, testing shall be done for:
a) mechanical soundness and leak tightness of pipes and fittings;
b) leak tightness of joints; and
c) Soundness of any construction work, in particular that of the anchorages.
• Site Test Pressure

The test pressure to be applied should be not less than any of the following:
a) The maximum sustained operating pressure,
b) The maximum static pressure plus 5 N/mm2, and
c) The sum of the maximum sustained operating pressure (or the maximum static
pressure) and the maximum calculated surge pressure.
• Test Procedure
• The completed pipeline may be tested either in one length or in sections; the
length of section depending upon:
a) availability of suitable water,
b) number of joints to be inspected, and
c) Difference in elevation between one part of the pipeline and another.
598
• Where the joints are left uncovered until after testing, sufficient material should
be backfilled over the centre of each pipe to prevent movement under the test
pressure.
• It is prudent to begin testing in comparatively short length of test section.
Progressively as experience is gained, lengths of about 1.5 km or more, are
tested in one section, subject to consideration of length of trench which can be
left open in particular circumstances.
• Each section should be properly sealed-off. Preferably with special stop ends
secured by adequate temporary anchors. All permanent anchors should be in
position and, if of concrete, should have developed adequate strength before
testing begins. The section under test should be filled with water, taking care
that all the air is displaced either through vents at the high points or by using a
pig or a sphere.
• After filling, the pipeline should be pressurized to the specified operating
pressure and left for a period of time to achieve stable conditions. The length of
this period of time depends on many factors such as slight movement of the
pipeline under pressure whether air is trapped in the pipeline or whether the
pipeline has a concrete lining which absorbs water.
• The pipeline is then pressurized up to the full test pressure and the section under
test completely closed off. The test should be maintained for a period of not less
than 10 minutes to reveal any defects in the pipes, joints or anchorages.
• Leak Detection Test

• If the test is not satisfactory, the fault should be found and rectified. Where there
is difficulty in locating a fault, the section under test should be subdivided and
each part tested separately.
• If any leakage is found during testing of pipeline, Contractor will have to
attend the same immediately and rectify at his cost. If Contractor fails to rectify
the defect, the entire length of pipeline between two adjacent outlets shall be
rejected. If any intermediate payment is made to the Contractor for portion
under rejection, the same shall be recovered from the outstanding dues of the
Contractor.
• Final Testing:
• After all sections have been joined together on completion of section testing, a
test on the complete pipeline should be carried out. This test should be carried
out at a pressure not less than the maximum sustained operating pressure or the
maximum static pressure of the pipeline and, during the test, inspection made
of all work which has not been subject to section tests. During the test, the
pressure at the lowest point in the pipeline should not exceed the maximum
given in following Table no. 7.
599
Table no-7 Maximum Field hydrostatic test pressure for ductile iron
pipelines with flexible joints

• Third party Inspection can be done form any one of the following services or
3 S.G.S, Mumbai.
5 VJTI, Mumbai.
curing tank and stores etc. shall be provided free of cost by the contractors.
(b) The materials shall be tested in QC laboratory or at any other place directed by
600
charge.
2 Laboratory Assistants(Twevlth Pass with Science
Two to Four
(As per work)
material)
(One for each L.A.)
• Following minimum equipments shall be available in the field laboratory setup

by the contractor.

detailed specifications or otherwise required by the Engineer-in-Charge, the
same shall be carried out at the laboratory, selected by the Engineer-in-Charge
at Contractor’s cost. The other tests of mortar, concrete, sand, coarse
aggregates etc. shall be carried out in field laboratory set up by the contractor
in presence of quality control representative at contractors cost. Contractor
shall through this procedure assure the quality of work.
601
supplied by the contractor. The samples for testing shall be taken in the
presence of Engineer-in-Charge or his representative /QC present on site. The
contractor or his authorized representative shall have a free access in these
laboratories, to get himself satisfied about procedures of testing etc. Even if the
contractor or his representative fails to remain present while collecting samples
or testing, the results will be considered as authentic and binding on the
contractor.
Laboratories) approved laboratories and from Quality Control, MERI
laboratories of the WRD. Contractor shall provide periodical quality assurance
report (Weekly/fortnightly/monthly) to Engineer in Charge along with proofs
in support of quality of material brought for the work, the process/ execution
of work is as per specification.
quality of work.
• If he fails to fulfill the above requirement, the required manpower for testing
and field laboratory with required equipments will be deployed by the Engineer
in charge and the charges for the same will be recovered from the contractor.

• All pipelines should be tested before being brought into service. The test should
be a hydrostatic test performed by filling the pipeline with water and raising the
pressure to the selected test pressure and maintaining this for a sufficient period
to allow for absorption of water by the pipe material.
• After a new pipeline is laid and jointed, testing shall be done for:
a) mechanical soundness and leak tightness of pipes and fittings;
b) leak tightness of joints; and
c) Soundness of any construction work, in particular that of the anchorages.
• The test pressure to be applied should be not less than any of the following:
a)The maximum sustained operating pressure,
b)The maximum static pressure plus 5 N/mm2, and
c)The sum of the maximum sustained operating pressure (or the maximum static
pressure) and the maximum calculated surge pressure.
• The completed pipeline may be tested either in one length or in sections; the
length of section depending upon:
a) availability of suitable water,
b) number of joints to be inspected, and
c) Difference in elevation between one part of the pipeline and another.
• Where the joints are left uncovered until after testing, sufficient material should
be backfilled over the centre of each pipe to prevent movement under the test
pressure.
• It is prudent to begin testing in comparatively short length of test section.
Progressively as experience is gained, lengths of about 1.5 km or more, are
tested in one section, subject to consideration of length of trench which can be
left open in particular circumstances.
602
• Each section should be properly sealed-off. Preferably with special stop ends
secured by adequate temporary anchors. All permanent anchors should be in
position and, if of concrete, should have developed adequate strength before
testing begins. The section under test should be filled with water, taking care
that all the air is displaced either through vents at the high points or by using a
pig or a sphere.
• After filling, the pipeline should be pressurized to the specified operating
pressure and left for a period of time to achieve stable conditions. The length of
this period of time depends on many factors such as slight movement of the
pipeline under pressure whether air is trapped in the pipeline or whether the
pipeline has a concrete lining which absorbs water.
• The pipeline is then pressurized up to the full test pressure and the section under
test completely closed off. The test should be maintained for a period of not less
than 10 minutes to reveal any defects in the pipes, joints or anchorages.
• Leak Detection - If the test is not satisfactory, the fault should be found and
rectified. Where there is difficulty in locating a fault, the section under test
should be subdivided and each part tested separately.
• If any leakage is found during testing of pipeline, Contractor will have to attend
the same immediately and rectify at his cost. If Contractor fails to rectify the
defect, the entire length of pipeline between two adjacent outlets shall be
Contractor.
• Final Testing - After all sections have been joined together on completion of
section testing, a test on the complete pipeline should be carried out. This test
should be carried out at a pressure not less than the maximum sustained
operating pressure or the maximum static pressure of the pipeline
• Third Party Inspection of PDN work shall be inspected, tested and certified by
PMC/TPI/QC. Modalities of PMC/TPI/QC Inspection shall be separately
decided and given by Engineer-In-charge.
The Hydraulic Testing of pipeline as laid or fixed shall be measured in Km correct to a

meter as specified by Engineer-in-charge and paid for separately under the relevant
item. The portion of the pipe overlapped at the joints shall not be included in the length
of pipe work. Excavation, refilling, anchor blocks, thrust blocks wherever required
shall be measured and paid for separately under relevant items of work.

D) 80% of the payment will be released after supplying, lowering, laying, jointing and
E) Balance 10% of the payment will be released after satisfactory hydraulic testing of
603
F) Remaining 10% amount will be withheld and it will be released after successful
of respective WUAs.

----------***----------
Note
Operation, Maintenance and Handing over of the System
a. The contractor shall operate and maintain the complete pipe distribution network
for the period of 5 (five) years after commissioning. Out of this period, during last
two years the operation of the schemes shall be done by the contractor jointly along
with WUA. On completion of O & M period, the system shall be handed over to
WUA
b. During rotation period, once in every year, the Contractor shall perform
hydraulic test to the satisfaction of Engineer In-charge to verify the flow of
designed discharge, detect or confirm any leakage in the system and rectify at his
own cost. The testing shall preferably be conducted jointly with members of
WUA/representative of Engineer In-charge, technical representative of contractor
and any other stake holder.
c. On completion of every Irrigation season, the contractor shall flush the pipe line
from its tail flush valve so that any siltation, vegetation or obstruction is cleaned
and pipe is able to flow designed discharge for next season.
d. During the O & M period, contractor shall give training to the members of WUA
about O & M of PDN work and its efficient use and protection of the system from
any damages.
e. The contractor shall prepare a detail map of the permanent marking along the
alignment of pipe and submit the same to Engineer In-charge. The Engineer In-
charge shall verify and endorse the location of the marking and handover these
signed maps as a permanent record to WUA. Along with this, the detailed Geo-
tagged map of laid pipeline shall also be handed over to WUA.
f. In association of the members of WUA, the Engineer In-charge shall confirm the
release of designed discharge through every outlet before handing over. In case of
any short fall or defect, it should be made good from the contractor at his own cost.
604
SPECIFICATION FOR POLYVINYL CHLORIDE (P.V.C.) PIPES
12.20 Providing and supplying in standard lengths ISI mark rigid un

plasticized PVC pipes (Item No. LIPDN 29)
Providing and supplying in standard lengths ISI mark rigid unplasticised PVC pipes
suitable for potable water with solvent cement joints including cost of couplers, as per
IS specification no. 4985 / 1988 excluding GST levied by GOI and GOM in all respect,
including transportation, freight charges, inspection charges, loading, unloading,
conveyance to the departmental stores and stacking the same in closed shed duly
protected from sun rays and rains including cost of jointing material i.e. solvent cement,
etc. complete (selffit type to be jointed with cement solvent).

This Specification covers requirements for Providing and supplying in standard lengths
ISI mark rigid unplasticised PVC pipes suitable for potable water with solvent cement
joints including cost of couplers, as per IS specification no. 4985-1888 excluding GST
levied by GOI and GOM in all respect, including transportation, freight charges,
inspection charges, loading, unloading, conveyance to the departmental stores and
stacking the same in closed shed duly protected from sun rays and rains including cost
of jointing material i.e. solvent cement, etc. complete (selffit type to be jointed with
cement solvent).

• Introduction
Polyvinyl Chloride (PVC) pipes are made by a continuous extrusion process. These
pipes are supplied with plain or with socket-ends. The Contractor shall provide onsite
training on PVC pipe laying, jointing, testing and maintenance etc. to the personnel
authorized by the Engineer-in-charge. The contractor should provide technical
Manual on PVC pipes including precautions to be taken during operation of the
pipeline.
The manufacturing, testing, supplying, laying, jointing and testing at work sites of PVC
Codes. In particular, the following standards, unless otherwise specified herein, shall
be referred. In all cases, the latest revision of the Codes shall be referred to. If
standards/Codes, this Specification shall govern. Others Codes not specifically
mentioned here but pertaining to the use of PVC Pipes form part of these Specifications.
605
IS - 4985 Unplastisized PVC pipes for potable water supplies.
IS- 4669 Methods of test for polyvinyl chloride resins
IS-10151 Specification for polyvinylchloride (PVC) & its copolymers for its
safe use in contact with foodstuffs pharmaceuticals & drinking
water.
IS-12235 Methods of tests for unplasticized PVC pipes.
IS 7634 (part-3) Laying & jointing of UPVC pipes.
• Raw Materials
• Raw material used to manufacture PVC Pipes is polyvinyl chloride.
• The material from which the pipes are made shall consist substantially of
polyvinyl Chloride conforming to I S :10151 to which may be added only those
additives that are absolutely needed to facilitate the manufacture of the pipe and
the production of sound durable pipe of good surface finish, mechanical strength
and opacity.
• The monomer content (VCM content) in the resin shall be within the limits
specified in IS 10151
• The composition shall be based on PVC resin having a k-value of 64 or greater
when tested in accordance with IS 4669
• The addition of the manufacturer’s own rework material is permissible. The
quantity of rework material used is to be declared by the manufacturer. No other
rework material shall be used.
The General manufacturing process of PVC Pipe is as given below.

The PVC resin and the additives are mixed in a heater/cooler mixer to form the PVC
compound.
Formed compound is fed into the extruder through a spiral flow conveyer and hopper
The compound gets molten in the heating zone of the extruder, which is then extruded into
pipes passing through a mandrel/die arrangement. Different mandrel/die combinations are
used for different pipe sizes.
In the vacuum sizing/pressure tank, the dimensions are controlled to within the tolerances
required.
The pipe is then passed through chilled water in a spray tank where the pipe attains its
rigidity.
The extruded pipe is passed through a traction (also called hauling) arrangement to extract
the pipe at a regulated speed. This also controls the dimensions of the pipe.
The pipes are then cut to size in a cutter
One end of the cut pipes is then processed for socketing. The pipe end is heated on a heating
coil and sleeved over a mandrel machined to the socket inner dimensions to get the socket
profile.
606
The pipe shall be classified by pressure ratings (working pressures) at 270as
follows.
Class of pipe Working pressure (PN)
Class 1 0.25 MPa (2.5 kg/cm2)

All PVC pipes in a single consignment of the same class, same size and manufactured
under essentially similar conditions shall constitute a lot. The number of test samples
to be taken from a lot shall depend on the size of the lot and the outside diameter of
the pipes, and shall be in accordance with following Table No.1.
Table No.1 Scale of Sampling for Visual Appearance and Dimensional Requirements
These pipes shall be selected at random from the lot and in order to ensure the
randomness of selection, a random number table shall be used. In the absence of a
random number table, following procedure may be adopted. Starting from any pipe
in the lot, count them as 1, 2, 3, etc. up to r and so on, where r is the integral part of
N/n, N being the number of pipes in the lot, and n is the number of pipes in the
sample. Every rth pipe so counted shall be withdrawn so as to constitute the required
sample size.
• The dimensional and visual requirements :

The number of pipes given for the first sample in col 3 of above Table No. 1 shall
be taken from the lot and examined for visual and dimensional requirements given
under dimensions. A pipe failing to satisfy any of these requirements shall be
607
considered as defective. The lot shall be deemed to have satisfied these
requirements, if the number of defectives found in the first sample is less than or
equal to the corresponding acceptance number given in col. 5 of Table 1. The lot
shall be deemed not to have met these requirements, if the number of defectives
found in the first sample is greater than or equal to the corresponding rejection
number given in col 6 of Table 1. If, however, the number of defectives found in
the first sample lies between the corresponding acceptance and rejection numbers
given in col 5 and 6, a second sample of the size given in col 3 shall be taken and
examined for these requirements. The lot shall be considered to have satisfied these
requirements if the cumulative sample is less than or equal to the corresponding
acceptance number given in col 5, otherwise not.
• Reversion Test, Vicat softening test, Density, Sulphated ash content test,
Resistant to external blows at 00c, Internal hydrostatic pressure test.
The lot having satisfied dimensional and visual requirements as mentioned above,
shall be tested for Reversion Test, Vicat softening test, Density, Sulphated ash
content test, Resistant to external blows at 00 c , internal hydrostatic pressure test as
mentioned below. A separate sample size for each of the test shall be taken as
stipulated in following Table no.2 (for Reversion Test, Vicat softening test and
Density test), Table no.3 (for Sulphated ash content test), Table no.4 (for Resistant
to external blows at 00 c) and Table no.5 (for internal hydrostatic pressure test).
Table 2 Scale of sampling for Reversion, Vicat Softening Temperature and Density Test
Number of pipes Sample Sample Cumulative Acceptance Rejection

in the Lot Number size Sample Number Number
size
(1) (2) (3) (4) (5) (6)

Up to 1000 First 5 5 0 2
Second 5 10 1 2
1001 to 3000 First 8 8 0 2

Second 8 16 1 2
3001 to 10000 First 13 13 0 2
Second 13 26 1 2
10001 and First 20 20 0 3
above Second 20 40 3 4
For dn above 110 mm
Up to 3000 Second 3 6 1 2
3001 to 10000 First 5 5 0 2
Second 5 10 1 2
10001 and First 8 8 0 2
608
Table 3 Scale of sampling for Sulphated Ash Content Test
Number Sample Sample Cumulative Acceptance Rejection
of pipes Number size Sample size Number Number
in the Lot
(1) (2) (3) (4) (5) (6)
Up to First 2 2 0 1
1000 Second 2 4 1 1
Above First 3 3 0 2
10000 Second 3 6 1 2
Table 4 Scale of sampling for Resistance to External Blows at 00C

Number of Sample Sample Cumulative Acceptance Rejection
pipes in the Number size Sample Number Number
Lot size
(1) (2) (3) (4) (5) (6)
Up to 3000 First 3 3 0 2
Second 3 6 1 2
3001 to First 5 5 0 2
10000 Second 5 10 1 2
10001 and First 8 8 0 2
Table 5 Scale of sampling for Internal Hydrostatic Test

Number of pipes in the Lot Sample size Acceptance Number

(1) (3) (6)
Up to 3000 2 0
3001 to 10000 3 0
10001 and above 5 0
The criteria for conformity of various test mentioned above shall be the same as that
for dimensional and visual requirements as mentioned in above para.

Pipe selected as per sampling criteria mentioned in earlier Para are subject to
following tests before delivery from factory.
1. Dimensions: Outside diameter, Wall thickness, Length of pipe

2. Visual appearance
3. Opacity
4. Effect on water
5. Reversion test,
6. Vicat’s Softening Test,
609
7. Density,
8. Sulphated ash content test
9. Resistant to external blows at 00 c
10.Internal hydrostatic pressure test
These tests shall be carried out by the agency in the presence of representative of
Engineer In-charge /WRD/QC/TPI.
• Dimensions
• The mean outside diameter, outside diameter at any point and wall thickness
of pipe shall be as given in following Table no.6
• Length
The length of pipe shall be 4,5 or 6 m. The pipe may be supplied in other lengths, as
agreed between the manufacturer and the purchaser.
• Visual Appearance
The colour of the pipes shall be light grey. Slight variations in the appearance of the
colour are permitted. The internal and external surfaces of the pipe shall be smooth,
clean and free from grooving and other defects. Slight shallow longitudinal grooves
or irregularities in the pipe shall be permissible provided the wall thickness remains
within the permissible limits.
• Opacity
The wall of the plain pipe shall not transmit more than 0.2 % of the visible light falling
on it when tested in accordance with IS 12235
• Effect on Water
The pipes shall not have any detrimental effect on the composition of water flowing
through them, when tested as per IS 12235. The limits of all the other toxic substances
shall not exceed the specified limit of 0.01 mg/l
• Reversion Test
When tested by the immersion method prescribed in IS 12235, a length of pipe 200 ±
20 mm long shall not alter in length by more than 5 percent. In the case of socket end
pipes, this test shall be carried out on the plain portion of the pipe taken at least
100mm away from the root of the socket.
• Vicat Softening temperature

When tested by the method prescribed in IS 6307, the Vicat softening temperature
of the specimen shall not be less than 80°C.
• Density
When determined in accordance with IS 13360, the density of the pipe shall be
between 1.40 and 1.46.
610
611
• Sulphated ash content test
When tested as per method prescribed in IS 4985, the sulphated ash content in the
pipe shall not exceed 11 percent.
• Resistance to external Blows at 00c

When tested by the method prescribed in IS 4985, the pipe shall have a True Impact
Rate of not more than 10 %
• Internal hydrostatic pressure test

When subjected to internal hydrostatic pressure test in accordance with the
procedure given in IS 12235, the pipe shall not fail during the prescribed test
duration. The temperature of test shall be minimum 270c and minimum holding time
(test duration) shall be 1 hour.
Each pipe shall be indelibly marked in English language at intervals of not more
than 3 m . The marking shall show the following.

2. Class of pipe and Pressure rating.
3. Outside diameter
inscribed.
The class of pipe shall also be colour coded on pipe as mentioned below.
Class of pipe Colour
Class 1 Red
Class 2 Blue
Class 3 Green
Class 4 Brown
Class 5 Yellow
Class 6 Black
• Transportation of Pipes
As PVC pipes are durable and light, they are more likely to be mishandled. Following
precautions shall be taken during transportation of pipes.
• When transporting pipes, flat bed vehicles should be used. The bed should be free
from nails and other projections. When practical, pipes should rest uniformly on the
vehicle over the whole length.
• The vehicles should have side supports approximately 2 m apart and the pipes
should be secured effectively during transport. All posts should be flat with no sharp
edges.
612
• When loading spigot and socket pipes, the pipes should be stacked on the vehicle so
that the sockets do not take excessive loads.
• Where pipes overhang the vehicle, the amount of overhang should not exceed I m.
• High stiffness pipes should be placed at the bottom of the load and low stiffness
pipes at the top.
• Care should be taken to avoid positioning the pipes near to any exhaust systems or
any other potential hazards such as diesel oil, paints or solvents.
• When pipes are transported in bundles, the bundles should be secured effectively
and off- loaded with due care.
• Mechanical lifting equipment used for lifting pipes and pipe bundles should not
damage the pipe. Fork-lift forks should be flat and protected. Cranes should have
spreader bars. No wire ropes, chains or hooks should be used. Slings should be made
of rope or webbing 7 to 10 cm wide.
• If pipes have been telescoped for transporting, the inner pipes should be removed
first and stacked separately.
• Stacking of Pipes
Following precautions shall be taken so as to eliminate potential damage to pipes
• Pipes should be stacked on a surface flat and free from sharp objects, stones or
projections in order to avoid deformation or damage. Ends of pipes should be
protected from abrasion and chipping.
• The pipes should be supported evenly over their whole length. The bottom layer of
the stack should be supported on wooden battens of unifrom size, at least 50 mm
wide and placed not more that 2 m apart. The sockets should not bear on the ground.
• Pipes of different diameters and different pressure classes should preferably be
stacked separately.
• Factory packed pipes should be packed in bundles with timber battens at minimum
three places. These should not be unpacked until required for use.
• It should be necessary to store pipes loose or if they are received loose, care should
be taken to see that each layer of the stack lies alternatively with the sockets on
opposite ends of the stack. The sockets of each pipe must project sufficiently for the
pipes to be supported correctly along the whole length (parallel stacking).
• The sides of the stack must be supported with timber battens to prevent stack
collapse. The side supports should be spaced not more than 3 m apart. The width of
the bottom layer should not exceed 3 m.
• Alternatively, pipes can also be stacked with adjacent layers lying at right angles to
each other (cross stacking).
• Stack height should not exceed 1.5 m in depots and stores or 1 m at construction
sites.
• Prolonged exposure of the pipes to sunlight must be avoided. Pipes must be protected
from ultra–violet light (sunlight), which would otherwise cause discolouration and
can reduce the impact strength of the pipe. Suitable protection by a free-venting
cover (canvas tarpaulin or polyethylene sheeting) is recommended if the total
exposed time is likely to exceed 4 weeks.
• Pipes should be stored away from any heat source and should not be in contact with
any other potential hazards such as diesel oils, paints or solvent.
• Valves
pipeline at various locations.
613
• Air Valve :
normal working stage, the air valve can discharge the small amount of gas gathered
in the pipe timely; finally, during the pump failure or maintenance stages, the air
valve will replenish the gas into the pipe to break the vacuum. According to the
orifice size, displacement and work pressure, air valve is divided into high pressure
trace exhaust valve, low pressure air release valve and combined air valve.
• Scour Valve :
• Control Valve :
D) Sliding Stem
• Globe valve
E) Rotary
• Butterfly valve
• Ball valve
F) Other
• Pinch valve
• Diaphragm valve
After delivery of pipes to worksite, additional test, if desired by Engineer-in-charge
shall be conducted on random samples of pipes collected from site. These tests shall be
as per those given in forgoing para.

Modalities of PMC / TPI / QC Inspection shall be separately decided and given by
Engineer In-charge.
Third party Inspection can be done from any one of the following services
614

2R.I.T.E.S. (Rail India Technical Economics Services)Mumbai
3 S.G.S Mumbai
4Vishveshvaraya National Institute of Technology, Nagpur
5VJTI, Mumbai
6CWPRS(Central Water & Power Research Station), Pune
7CIPET (Central Institute of Plastics Engineering & Technology)
and periodical tests to be carried out on materials mixes and placed concrete,
mortar etc. shall be specified by the Engineer In-charge from time to time and
the Contractor shall provide free of cost all facilities towards collections of
samples etc. unless otherwise specified. Labours for collecting samples and
transportation of the samples to quality control authorities for test shall be
provided free of cost by the contractor. Also electricity, fuel, water curing tank
and stores etc. shall be provided free of cost by the contractors.
• The materials shall be tested in QC laboratory or at any other place directed by
concern authority and the results given by such authorities shall be considered to
determine whether all materials, workmanship are of respective standard
• Testing charges for testing of Cement, TMT bars, all types of pipes and specials
• The Contractor shall make suitable arrangements to see that one of his
incurred by the Engineer-In-charge when the Contractor fails to provide required
men and materials for collecting samples and or their transport shall be recovered
from the Contractor.

charge.
615
Quality Assurance.

2 Laboratory Assistants(Twelveth Pass with
Two to Four
Science subject with 2 year experience in testing
(As per work)
of material)
(One for each
L.A.)


1 Earth Work – Field density, Moisture Content,
Field testing Equipments Sieves for Sand & Metal.

Contractor’s cost. The other tests of mortar, concrete, sand, coarse aggregates etc.
shall be carried out in field laboratory setup by the contractor in presence of quality
control representative at contractors cost. Contractors hall through this procedure
assure the quality of work.
of Engineer-in-Charge or his representative/QC present on site. The contractor or
representative fails to remain present while collecting samples or testing, the
results will be considered as authenticate binding on the contractor.
Laboratories) approved laboratories and from Quality Control, MERI laboratories
of the WRD. Contractor shall provide periodical quality assurance report
of quality of material brought for the work, the process/ execution of work is as
per specification.
616
quality of work.
• If he fails to fulfil the above requirement, the required manpower for testing and

• Pipe selected as per sampling criteria mentioned in earlier Para are subject to
1. Dimensions : Outside diameter, Wall thickness, Length of pipe
3. Opacity
4. Effect on water
5. Reversion test,
6. Vicat’s Softening Test,
7. Density,
8. Sulphated ash content test
9. Resistant to external blows at 00 c
10. Internal hydrostatic pressure test
• These tests shall be carried out by the agency in the presence of representative of
Engineer In-charge /WRD/QC/TPI.
Party Certification mark for each lot , Name of Department/Project for which pipes
are manufactured. Any other important matter that the manufacturer or purchaser
deems fit to be inscribed etc.
• When transporting pipes, flat bed vehicles should be used. The bed should be
free from nails and other projections. When practical, pipes should rest uniformly
on the vehicle over the whole length.
• The vehicles should have side supports approximately 2 m apart and the pipes
should be secured effectively during transport. All posts should be flat with no
sharp edges.
• When loading spigot and socket pipes, the pipes should be stacked on the vehicle
so that the sockets do not take excessive loads.
• Where pipes overhang the vehicle, the amount of overhang should not exceed I m.
• High stiffness pipes should be placed at the bottom of the load and low stiffness
pipes at the top.
• Care should be taken to avoid positioning the pipes near to any exhaust systems or
any other potential hazards such as diesel oil, paints or solvents.
• When pipes are transported in bundles, the bundles should be secured effectively
and off- loaded with due care.
• Mechanical lifting equipment used for lifting pipes and pipe bundles should not
damage the pipe. Fork-lift forks should be flat and protected. Cranes should have
spreader bars. No wire ropes, chains or hooks should be used. Slings should be
made of rope or webbing 7 to 10 cm wide.
• If pipes have been telescoped for transporting, the inner pipes should be removed
first and stacked separately.
• Pipes should be stacked on a surface flat and free from sharp objects, stones or
projections in order to avoid deformation or damage. Ends of pipes should be
protected from abrasion and chipping.
617
• The pipes should be supported evenly over their whole length. The bottom layer
of the stack should be supported on wooden battens of uniform size, at least 50
mm wide and placed not more that 2 m apart. The sockets should not bear on the
ground.
• Pipes of different diameters and different pressure classes should preferably be
stacked separately.
• Factory packed pipes should be packed in bundles with timber battens at minimum
three places. These should not be unpacked until required for use.
• It should be necessary to store pipes loose or if they are received loose, care should
be taken to see that each layer of the stack lies alternatively with the sockets on
opposite ends of the stack. The sockets of each pipe must project sufficiently for
the pipes to be supported correctly along the whole length (parallel stacking).
• The sides of the stack must be supported with timber battens to prevent stack
collapse. The side supports should be spaced not more than 3 m apart. The width
of the bottom layer should not exceed 3 m.
• Alternatively, pipes can also be stacked with adjacent layers lying at right angles
to each other (cross stacking).
• Stack height should not exceed 1.5 m in depots and stores or 1 m at construction
sites.
• Prolonged exposure of the pipes to sunlight must be avoided. Pipes must be
protected from ultra–violet light (sunlight), which would otherwise cause
discolouration and can reduce the impact strength of the pipe. Suitable protection
by a free-venting cover (canvas tarpaulin or polyethylene sheeting) is
recommended if the total exposed time is likely to exceed 4 weeks.
• Pipes should be stored away from any heat source and should not be in contact
with any other potential hazards such as diesel oils, paints or solvent.
Measurement
• The net length of pipes as laid or fixed shall be measured in running meters correct
to a cm. Specials shall be excluded and measured in running meters or numbers as
specified by Engineer-in-charge and paid for separately under the relevant item.
The portion of the pipe overlapped at the joints shall not be included in the length
of pipe work. Excavation, refilling, anchor blocks, thrust blocks wherever required
shall be measured and paid for separately under relevant items of work.
replacement for such pipes has to be made by the Contractor without any extra
cost as directed by the Engineer-in-Charge.
• Payment
618
• 80% of the payment will be released after supplying, lowering, laying, jointing and
• Balance 10% of the payment will be released after satisfactory hydraulic testing of
• Remaining 10% amount will be withheld and it will be released after successful
of respective WUAs.

----------***----------
619
12.21 Lowering, laying and jointing with P.V.C. pipes and specials
(Item No. LIPDN 30)
Lowering, laying and jointing with P.V.C. pipes and specials of following class and
diameter including cost of conveyance from stores to site of works including cost of all
labour, material, except cement solvent, rubber ring, as per IS code, etc. complete (with
cement solvent joint / ring fit joint) (for all class of pipes)
This specification covers the requirements for successfully, lowering, laying, jointing
and testing at works and site of P.V.C. Pipes used for water supply.

brushwood, rubbish of all kinds, loose stones and all other objectionable materials
shall be removed by the Contractor. Buried irrigation pipeline, and other structure, if
any, shall be removed by the Contractor. The ownership of all the usable material, so
removed from clearing site and/or excavation shall rest with the Engineer In-charge.
Useful material shall be stacked as directed. The Contractor shall dispose off all un-
useful materials as directed by the Engineer In-charge.
• Demarcation
All materials such as pegs, bamboo’s and strings and templates for marking out slopes,
The centre line of excavation shall be clearly marked by pegs or by stones at each
of the centre line, beyond the canal edges so that they are not disturbed during the
for construction activity at his own cost.

• Benchmarks fixed by the Survey of India and temporary benchmarks established by the
Engineer In-charge in vicinity of PDN work will serve as control points for these works.
The Contractor shall establish sufficient number of reference benchmarks for
• Before starting any work, the Contractor shall erect reference benchmarks, reference
The benchmark concrete block shall be 200 mmx200mm x600mm with 400mm
620
benchmark.
• The check profile shall be located 30m apart or closer as directed by the Engineer In-
• (All materials, labour and equipments (theodolites, levels, distometre, etc.) for setting
supplied by the Contractor at his cost. For this following numbers of minimum
Contractor.

2. Theodolites (Accuracy1second) 1 No.
3. Levels 2 Nos.
4. Staves 4 Nos.
All equipments shall be of standard and approved make and precision, and shall
be made available in advance of starting of the work. All equipments shall be
maintained, repaired and got tested and certified as and when required for its
accuracy from the standard test house or from the manufactures and to the
satisfaction of the Engineer-In-Charge.

the drawing or as directed by Engineer In -charge. Contractor must assume all
mm.
Engineer In-charge. Un-useful material from excavation shall be deposited in
spoils as and where directed by Engineer-In-charge.
excavation shall be diverted to nearby drain/nalla by cutting an open channel from
trench. When the drain/nalla bed is higher than the sub-soil water level met with,
the bailing out by suitable means of pumping shall be resorted to for dewatering
sub-soil water below the drain/nalla bed level. No distinction shall be made as to
whether the material being excavated is dry, moist, wet or slushy. The Contractor
shall have to excavate the PDN pipe trench and structure in under water level
conditions also i.e. under wet/slushy condition after providing sufficient
arrangement of dewatering. The material excavated under water level condition
which requires intermediate stacking for drying shall have to be re-handled. No
621
extra payment for efforts for drying out of soil, re-handling of dry soil, etc. shall
be given. No payment for extra efforts for excavation under this condition shall be
made.
• Over excavation performed by the Contractor for any purpose or reason, except
for additional excavation as may be directed by the Engineer-In-charge, shall be
excavation using the material as directed by the Engineer In- Charge shall also be
at the cost of the Contractor.
and structure shall be over excavated to the extent as directed by the Engineer In
soil to be placed in uniformly compacted layers as directed by the Engineer In
• Laying of Pipes
While laying of PVC pipes all precautions as mentioned in IS 7634 (part-3)
shall be taken.
pipes that are approved by Engineer-in-Charge shall be laid.
• The trench bottom shall be constructed to provide a firm, stable and uniform
support for the full length of the pipeline. There should be no sharp objects that
may cause point loading.
• A minimum bedding thickness of 100 to 150 mm under the pipe shall be provided
by watering and compaction
• For pipes of diameter 100 mm or greater, bell holes in the bedding , under each
socket joint, shall be provided by removing some of the bedding material, to
accommodate the larger diameter of the joint and to permit the joint to be made
properly.
• The pipes shall be preferably laid with the spigots entered into the sockets in the
same direction as the intended flow of water.
• To sustain thrust caused by internal pressure, concrete anchor blocks should be
provided at all changes of direction, tees, blank ends, large reductions in diameter
and valves.
• Metal marker tape can be laid into the final backfill to enable electronic location
of the pipe line, if required.
Jointing of pipes shall be done as per procedure mentioned in IS 7634 (Part-3).
Commonly used joints are as follows
a) Solvent welded joints

b) Integral elastomeric sealing ring joints,
c) Mechanical compression joints
d) Flanged joints
e) Screwed or threaded joints, and
f) Union coupled joints
622
• Solvent welded joints
These are permanent in nature and can withstand axial thrust (end – load bearing)
This technique is used with plain ended pipes with couplers, for pipes with integral
socket as well as with injection mouleded fittings.
Solvent cement consists essentially of a solution of vinyl chloride polymer or

copolymer dissolved in a suitable volatile mixture of organic solvents. The solvent
constituents soften the mating surfaces, which difuse into one anther to from a “cold
weld”.Solvent cement shall confrom to all requirements of IS 14182
PVC solvent cement is quick drying, therefore it shall be applied as quickly and
carefully as possible and in consistence with good workmanship.For larger sizes, it is
advisable for two workers to work simultaneously on the pipe and socket.Within 20
sec after the last application of solvent cement, insert the pipe into socket in a single
steady and every controlled but forceful action.
• Integral elastomeric sealing ring joints.

• Elastomeric sealing ring joints consists of an elastomeric sealing element located in the
socket formed integrally with the pipe or fitting. The sealing element (sealing ring) is
automatically compressed to from a pressure tight seal when the spigot of the pipe is
inserted into the socket.
• These joints are non-end load bearing and it is essential to ensure the probability of
joint separation due to axial thrust. Joint separation can be prevented in below ground
applications by incorporating concrete anchor blocks at appropriate places.
• In order to meet water quality and biodegradation requirements, elastomeric sealing
rings are usually made from synthetic materials like ethylene-propylene-diene (EPDM)
copolymer, styrenebutadiene rubber (SBR) or a combination of synthetic and natural
rubber. The material should conform to IS 5382
• Mechanical Compression joints

These are commonly separate fittings made from UPVC or metal and can be in the
form of a coupler for connecting pipes and fittings of the same material and of the
same dimensions, or as an adaptor for connecting components of different materials
and / or dimensions. Generally compressor fittings consists of four main elements:
body, elastomeric sealing rings, backing(compression) rings and bolts. Both pipe ends
should be clean and free from damage before assembly is begun. Each element is
positioned on the pipe separately, centered over the joint and the sealing rings
compressed between the body of the fitting and the pipe by tightening the back rings.
Bolts should not be over tightened.
623
• Flanged joints
These are used for jointing of UPVC pipes to other pipes, fittings, valves and vessels
made from dissimilar materials, for example metals. The joint is made by compressing
a gasket or elastomeric sealing ring between the mating surfaces of the flanges.
• Screwed or threaded joint

These are similar to the joints used with metal pipes. If the pipe has to be joined by
screw threads, only thick walled pipe should be used and cut with taper threads. Some
manufacturers supply pipes with factory cut threads. Threaded pipes shall not be
subjected to a pressure exceeding two-thirds of the rating for unthreaded pipes.
Injection moulded threaded joints are used for jointing PVC to metal pipes. Injection
moulded threads are less notch sensitive than cut threads.
• Union Coupled joint

This is a form of flanged joint, but the faces are held together by a screwed connection.
A composite metal and PVC socket union is a very satisfactory method of jointing
PVC to screwed metallic fittings.

• The type of material used for backfilling and the manner of depositing the material,
shall be subject to approval by the Engineer-in-Charge. The backfill material shall be
placed to the line and grades as shown on drawings or as prescribed in this paragraph
or as directed by the Engineer-in-Charge.
• The backfill material shall be placed carefully and spread in uniform layers of not more
than 15cm thickness, with the first layer watered and compacted by stamping or by
mechanical means. The backfill shall be brought up as uniformly as practicable on both
sides of pipe to prevent unequal loading.
• Only soft earth and gravel of good quality free from boulder, roots, vegetable matters
etc. shall be used for refilling of trench up to 300mm above the top of the pipe. If
sufficient quantity of suitable (Sharp edge stone free) excavated earth is not available,
the trench shall be filled by borrowed gravel material up to 300 mm above top of
pipeline. Remaining trench can be filled with available material.
• When compacting the soil against steep rock, abutment walls of concrete structures,
rollers shall not be used close to structures as structural damage is very likely more
particularly when structures have not been fully cured. The size and weight of
equipment will depend on nature of material, the height and load assumed in design of
structure. The backfill close to the structure up to the rolled layer shall be compacted
in suitable uniform layers, using pneumatic / hand tampers as appropriate for dry
density at average bulk density (+/- 10%). The moisture content of the earth fill placed
against the rock or the structure shall be on higher/lower side of OMC by about 2% or
so, to allow it to be compacted. Profuse watering shall be done to pervious materials
(sand) before compaction as per instruction of the Engineer-in-Charge. Compaction at
624
junction of earthwork and backfill around the structure shall be carried out with special
care.
• The trench shall be refilled so as to built-up the original ground level.
boundaries so as they will not be disturbed during the agricultural activities of the
farmers.
• The marking shall be constructed in prefabricated concrete block of size (15x15x45)
CM embedded in concrete block of size (30x30x30) CM. The base of this block shall
be buried in ground projecting only 15cm above the ground and the base concrete
block.
• These blocks shall be able to locate the pipeline as and where it is laid all over the
work. The contractor shall mark each block with specific distinct identification mark.
representative, representative of WUA, concern farmers sharing the boundaries, TPI,
any other stake holders in the command.
period of the contract. Any damage done to these blocks for the reasons whatsoever
shall be made good at the cost of contractor.
• The contractor shall submit the location of such blocks with specific identification
marks with schedule on a special command area map.
• The map of marking of the block shall be handed over to WUA while handing over
the command area.
• The Geotagging map showing Latitude and Longitude value of each apex of laid
pipeline shall be submitted to Department and WUA for future reference.
• The contract shall fix information boards of 1.2 m x 0.9 m size at various location as
directed by Engineer-in-charge. On this boards, salient features of the work (eg. Pipe
diameter, pipe type, discharge, any other specific details suggested by Engineer-In-
Charge) shall be written.

charge.
and Calibration Laboratories)
• Engineers India Limited, Mumbai
• R.I.T.E.S. (Rail India Technical Economics Services) Mumbai
• S.G.S Mumbai
• Vishveshvaraya National Institute of Technology , Nagpur
• VJTI , Mumbai
• CWPRS (Central Water & Power Research Station), Pune
• CIPET (Central Institute of Plastics Engineering & Technology)
625

Quality Assurance.

2 Laboratory Assistants(Twelveth Pass with
Two to Four
(As per work)
of material)
(One for each L.A.)
626

for Sand & Metal.

per specification.
quality of work.

• The Contractor shall clear the entire area required for setting out. All tree
stumps, roots, brushwood, rubbish of all kinds, loose stones and all other
objectionable materials shall be removed by the Contractor.
• All materials such as pegs, bamboo’s and strings and templets for marking out
slopes, and labour required for lineout should be provided by the Contractor at
his own cost.
• The center line of excavation shall be clearly marked by pegs or by stones at
each chain or change of direction or at shorter intervals on curves, in the
beginning. The final lineout will be done by fixing references to neat suitable
distances on either side of the center line, beyond the canal edges so that they
are not disturbed during the construction period.
627
• Benchmarks fixed by the Survey of India and temporary benchmarks
established by the Engineer In-charge in vicinity of PDN work will serve as
control points.
• Prior permission of other department like P.W.D., H.P.C.L, M.J.P. shall be
taken if the alignment of pipe line crosses railway line, roads, gas pipe lines
etc.
• Before starting any work, the Contractor shall erect reference benchmarks,
reference lines and check profiles at convenient locations approved by the
Engineer In-Charge.
• All materials, labour and equipments (theodolites, levels, distometre, etc.) for
setting out works including construction of benchmarks in concrete, reference
lines, check profiles and surveys as may be required at the various stages of
construction shall be supplied by the Contractor at his cost.
• Excavation of pipe trenches shall be carried out as per excavation line shown
in the drawing or as directed by Engineer In-charge.
• The usable excavated material available from the excavated trenches(PDN)
shall be used in backfilling. If such usable material is in excess of the
requirement of backfilling, the same shall be deposited in the spoils as and
where directed by the Engineer In-charge.
• In the PDN and structure section where expansive type of the soil such as CH
type of soil is encountered and over which PDN cannot be directly laid, the
PDN trench and structure shall be over-excavated to the extent as directed by
the Engineer In-Charge and such over-excavated section shall be filled with
suitable murum type soil to be placed in uniformly compacted layers as directed
by the Engineer In-Charge.The over excavation made in such strata, filling by
suitable soil,and watering and compacting such soil will be paid separately
under relevant items. Above provision for over-excavating and filling with
suitable murum type or good soil available material shall be applicable in case
such treatment is found essential.
• While laying of PVC pipes all precautions as mentioned in IS 7634 (part-3)
shall be taken.
drawings.
pipes that are approved by Engineer-in-Charge shall be laid.
• The trench bottom shall be constructed to provide a firm, stable and uniform
support for the full length of the pipeline. There should be no sharp objects that
may cause point loading.
• A minimum bedding thickness of 100 to 150 mm under the pipe shall be
provided by watering and compaction
• For pipes of diameter 100 mm or greater, bell holes in the bedding , under each
socket joint, shall be provided by removing some of the bedding material, to
accommodate the larger diameter of the joint and to permit the joint to be made
properly.
• The pipes shall be preferably laid with the spigots entered into the sockets in
the same direction as the intended flow of water.
provided at all changes of direction, tees, blank ends, large reductions in
diameter and valves.
• Metal marker tape can be laid into the final backfill to enable electronic
location of the pipe line, if required.
628
• Jointing of pipes shall be done as per procedure mentioned in IS 7634 (Part-
3).
• The backfill material shall be placed carefully and spread in uniform layers of
not more than 15cm thickness, with the first layer watered and compacted by
stamping or by mechanical means. The backfill shall be brought up as
uniformly as practicable on both sides of pipe to prevent unequal loading.
• Only soft earth and gravel of good quality free from boulder, roots, vegetable
matters etc. shall be used for refilling trench up to 300mm above top of pipe.
If sufficient quantity of suitable (Sharp edge stone free) excavated earth is not
available, the trench shall be filled by borrowed gravel material up to 300 mm
• The moisture content of the earth fill placed against the rock or the structure
shall be on higher/lower side of OMC by about 2% or so, to allow it to be
compacted. Profuse watering shall be done to pervious materials (sand) before
compaction as per instruction of the Engineer-in-Charge.
• Compaction at junction of earthwork and backfill around the structure shall be
• The contractor shall establish the sufficient number of reference blocks for
permanent marking on the alignment of PDN preferably at the interval of 30m
or as suitable on the field boundaries so as they will not be disturbed during the
agricultural activities of the farmers.
pipes are required as per the detailed specifications or otherwise required by
the Engineer-in-Charge, the same shall be carried out at the laboratory, selected
by the Engineer-in-Charge at Contractor’s cost.

• Measurement
The net length of Lowering, Laying & Jointing of pipes as laid or fixed shall be
measured in running meters correct to a cm. Specials shall be excluded and measured
in running meters or numbers as specified by Engineer-in-charge and paid for
separately under the relevant item. The portion of the pipe overlapped at the joints shall
not be included in the length of pipe work. Excavation, refilling, anchor blocks, thrust
blocks wherever required shall be measured and paid for separately under relevant
items of work.
• Payment
shall be as under:-
respective WUAs.
629
• After Successful Operation and Maintenance for First year-2%

• After Successful Operation and Maintenance for Second year-2%
• After Successful Operation and Maintenance for Third year-2%
• After Successful Operation and Maintenance for Fourth year-2%
• After Successful Operation and Maintenance for Fifth year-2%
A certificate regarding smooth working of pipe distribution network from the Chairman
of WUA shall be binding for annual release of this amount.
----------***----------
630
12.22 Providing and supplying ISI mark P.V.C. pipes fitting/specials
(Item No. LIPDN 31)
Providing and supplying ISI mark P.V.C. pipes fitting/specials including loading,
unloading , transportation up to departmental store, stacking excluding GST levied by
GOI & GOM in all respect. etc. complete.

This specification covers the requirements for providing and supplying ISI mark P. V.
C. pipes fitting / specials including loading, unloading, transportation up to
departmental store, stacking excluding GST levied by GOI & GOM in all respect. etc.
complete.

• Introduction
Polyvinyl Chloride (PVC) pipes are made by a continuous extrusion process. These
pipes are supplied with plain or with socket-ends.
The Contractor shall provide on site training on PVC pipe laying, jointing, testing
and maintenance etc. to the personnel authorized by the Engineer-in-charge. The
contractor should provide technical Manual on PVC pipes including precautions to be
taken during operation of the pipeline.
The manufacturing, testing, supplying, laying, jointing and testing at work sites of PVC
Codes. In particular, the following standards, unless otherwise specified herein, shall
be referred. In all cases, the latest revision of the Codes shall be referred to. If
mentioned here but pertaining to the use of PVC Pipes form part of these Specifications.
IS - 4985 Unplasticized PVC pipes for potable water supplies.

IS-10151 Specification for polyvinylchloride (PVC) & its copolymers for its
safe use in contact with foodstuffs pharmaceuticals& drinking
water.
IS 7634 (part-3) Laying & jointing of UPVC pipes.
631
• Raw Materials
• Raw material used to manufacture PVC Pipes is polyvinyl chloride.
• The material from which the of polyvinyl Chloride conforming to I S :10151 to
which may be added only those additives that are absolutely needed to facilitate
the manufacture of the pipe and the production of sound durable pipe of good
surface finish, mechanical strength and opacity.
• The monomer content (VCM content) in the resin shall be within the limits
• The composition shall be based on PVC resin having a k-value of 64 or greater
when tested in accordance with IS 4669
• The addition of the manufacturer’s own rework material is permissible. The
quantity of rework material used is to be declared by the manufacturer. No other
rework material shall be used.
The General manufacturing process of PVC Pipe is as given below.

The PVC resin and the additives are mixed in a heater/cooler mixer to form the PVC
compound.
Formed compound is fed into the extruder through a spiral flow conveyer and hopper
The compound gets molten in the heating zone of the extruder, which is then extruded into
pipes passing through a mandrel/die arrangement. Different mandrel/die combinations are
used for different pipe sizes.
In the vacuum sizing/pressure tank, the dimensions are controlled to within the tolerances
required.
The pipe is then passed through chilled water in a spray tank where the pipe attains its
rigidity.
The extruded pipe is passed through a traction (also called hauling) arrangement to extract
the pipe at a regulated speed. This also controls the dimensions of the pipe.
The pipes are then cut to size in a cutter
One end of the cut pipes is then processed for socketing. The pipe end is heated on a heating
coil and sleeved over a mandrel machined to the socket inner dimensions to get the socket
profile.
The pipe shall be classified by pressure ratings (working pressures) at 270as follows.
Class of pipe Working pressure (PN)

632
• Valves
• Air Valve :
three areas: firstly, in the water filled stage of the pipeline, filled with water by a
certain velocity, the air valve can discharge the remained gas in the pipe; secondly,
at the normal working stage, the air valve can discharge the small amount of gas
gathered in the pipe timely; finally, during the pump failure or maintenance stages,
the air valve will replenish the gas into the pipe to break the vacuum. According to
the orifice size, displacement and work pressure, air valve is divided into high
pressure trace exhaust valve, low pressure air release valve and combined air valve.
• Scour Valve :
• Control Valve :
• Sliding Stem
• Globe valve
• Rotary
• Butterfly valve
• Ball valve
• Other
• Pinch valve
• Diaphragm valve

Engineer In-charge.
633

• S.G.S Mumbai
• Vishveshvaraya National Institute of Technology , Nagpur
• VJTI , Mumbai

634
charge.
Quality Assurance.
1 Quality Assurance Engineer(Civil One

Engineering Graduate with 2 Year
experience in QA testing and report
generation work)
2 Laboratory Assistants(Twelfth Pass Two to Four

with Science subject with 2 year
experience in testing of material) (As per work)
(One for each L.A.)

1 Earth Work – Field density, Moisture

Content, Sieves for Sand &
Field testing Equipments Metal.
2 Concrete Work - Silt, Gradation, Moisture

Content, Slump, Cube
Moulds&CTM

635
per specification.
quality of work.

• All fittings/specials shall be fabricated or moulded at factory only. No fabrication
or moulding will be allowed at site, unless specifically permitted by the Engineer-
in-Charge.
Engineer-in-Charge at Contractor’s cost

• Measurement
The Specials of pipes as laid or fixed shall be measured in running meters correct
to a cm as specified by Engineer-in-charge and paid for separately under the
relevant item. The portion of the pipe overlapped at the joints shall not be included
in the length of pipe work. Excavation, refilling, anchor blocks, thrust blocks
wherever required shall be measured and paid for separately under relevant items
of work.

The break up to payment for supplying, laying, jointing & hydraulic testing of
pipe line shall be as under:-
of respective WUAs.
•After Successful Operation and Maintenance for First year-2%

•After Successful Operation and Maintenance for Second year-2%
•After Successful Operation and Maintenance for Third year-2%
•After Successful Operation and Maintenance for Fourth year-2%
•After Successful Operation and Maintenance for Fifth year-2%
----------***----------
636
12.23 Hydraulic testing of PVC pipe line to specified pressure (Item No.
LIPDN 32)
Hydraulic testing of PVC pipe line to specified pressure including cost of all materials
and labour and water for testing for specified length including cutting, placing end cap
making arrangement for filling safe water using reciprocating type pumps which should
be able to provide specified test pressure gauges and other necessary equipments,
labour, operation charges, etc. required for testing. The rate under this item shall also
include cost of retesting, if necessary and reinstating to original position.

This specification covers the requirements for hydraulic testing at works and site
of P. V.C Pipes used for water supply, including cost of all materials and labor and
water for testing for specified length including cutting, placing end cap making
arrangement for filling safe water using reciprocating type pumps which should be able
to provide specified test pressure gauges and other necessary equipments, labor,
operation charges, etc. required for testing. The rate under this item shall also include
cost of retesting, if necessary and reinstating to original position.

• Field Testing of Pipeline system.
• General
All pipelines should be tested before being brought into service. The test should
be a hydrostatic test performed by filling the pipeline with water and raising the
pressure to the selected test pressure and maintaining this for a sufficient period to
allow for absorption of water by the pipe material.

The test should confirm to following conditions
• be carried out at ambient temperature;

• be applied for at least 1 h, but not more than 24 h; and
• not exceed 1.5 times the maximum rated pressure of the lowest rated
component.
• Test Procedure
• Pipe systems should be hydraulically tested in lengths appropriate to the
diameters and site conditions. Pipelines longer than 800 m may require testing
in sections. Preferably, the length selected for test is between 300 m and 500
m.
• Testing should not take place until any concrete used for anchoring has fully
cured (normally 72 h) and attained its required strength. Solvent cemented
joints must be allowed to harden for a minimum of 24 h before being subjected
to test conditions.
• It is important to provide sufficient backfill over the main barrel of the pipe, to
prevent displacement and to maintain stable temperature conditions. Leave
joints free for inspection.
• The test position should be located at the lowest point of the pipeline profile to
encourage expulsion of air as the pipe is being filled with water. Adequate air
release mechanisms should be located at all high points along the line.
637
• Before filling the pipeline, all line valves and air venting systems should be
checked open. All air must be removed from the system.
• Fill the system slowly. Water velocity must not exceed 0.6 m/s. Potable water
pipelines should be tested with potable water only. After charging, close all air
valves and check proper action of automatic valves.
• Allow the system to stabilize under a nominal pressure for a minimum of 2
hours. Apply pressure steadily. Observe pressure gauges throughout and record
the rates of pressure increase.
• The pressure should be increased till the specified pressure is reached at the
lowest part of the section. Maintain test pressure at this level, by additional
pumping if necessary, for a period of 1 hour.
• Close all valves and disconnect the pressurizing unit. No further water should
be allowed to enter the system for a further period of 1 hour.
• During the test period, carry out a visual examination of all joints and exposed
connections.
• Leak Detection
• There should be no leakage in any part of the section.
• If there has been a decrease in pressure during this period other than due to
leakage, the original pressure is re-established by injecting a measured quantity
of water into the section.
• The test is considered to be satisfactory if
• there is no decrease in pressure (a slight rise in pressure is also, possible due
to changes in ambient temperatures),
• the measured quantity of water required to reinstate the pressure to the original
test pressure is less than the ‘permissible maximum’ Q,
Where,
Q = 4.5 liters per 1.6 km per 25 mm of nominal bore per 30 m head of test
pressure per 24 hours.
• On completion of any test, the residual pressure should be released slowly and
in a carefully controlled manner.
• All defects revealed in the test should be rectified and the procedure repeated
until a satisfactory result is obtained.
• If any leakage is found during testing of pipeline, Contractor will have to
attend the same immediately and rectify at his cost. If Contractor fails to rectify
the defect, the entire length of pipeline between two adjacent outlets shall be
Contractor.
charge.
Third party Inspection can be done form any one of the following services or from
any other mutually agreed agency.
• R.I.T.E.S. (Rail India Technical Economics Services)Mumbai
638
• S.G.S, Mumbai
• Vishveshvaraya National Institute of Technology, Nagpur
• VJTI, Mumbai
• CWPRS(Central Water & Power Research Station), Pune
•Testing of materials
Also electricity, fuel, water curing tank and stores etc. shall be provided free of cost
by the contractors.
• The materials shall be tested in QC laboratory or at any other place directed by the
• The Contractor shall make suitable arrangements to see that one of his representatives
setup including Quality Assurance Engineer backed with suitable laboratory assistants,
labours and well equipped laboratory for taking necessary field test required as per
specifications and as per instructions of Engineer in charge.
639
2 Laboratory Assistants(Twevlth Pass with
Two to Four
(As per work)
of material)
(One for each L.A.)
Following minimum equipments shall be available in the field laboratory


for Sand & Metal.

Slump, Cube Moulds&CTM
the testing of construction materials, pipes are required as per the detailed specifications
or otherwise required by the Engineer-in-Charge, the same shall be carried out at the
laboratory, selected by the Engineer-in-Charge at Contractor’s cost. The other tests of
mortar, concrete, sand, coarse aggregates etc. shall be carried out in field laboratory
setup by the contractor in presence of quality control representative at contractors cost.
Contractor shall through this procedure assure the quality of work.
• The materials, mixes and any other arrangements, including abours, shall be supplied
authenticate binding on the contractor.
specification.
work.
640
12.23.4Sequence of Execution
• All pipelines should be tested before being brought into service. The test should be a
hydrostatic test performed by filling the pipeline with water and raising the pressure to
the selected test pressure and maintaining this for a sufficient period to allow for
absorption of water by the pipe material.
• The test should confirm to following conditions
1. be carried out at ambient temperature;
2. be applied for at least 1 h, but not more than 24 h; and
3. Should not exceed 1.5 times the maximum rated pressure of the lowest rated
component.
• Pipe systems should be hydraulically tested in lengths appropriate to the diameters
and site conditions. Pipelines longer than 800 m may require testing in sections.
Preferably, the length selected for test is between 300 m and 500 m.
• Testing should not take place until any concrete used for anchoring has fully cured
(normally 72 h) and attained its required strength. Solvent cemented joints must be
allowed to harden for a minimum of 24 h before being subjected to test conditions.
• It is important to provide sufficient backfill over the main barrel of the pipe, to prevent
displacement and to maintain stable temperature conditions. Leave joints free for
inspection.
encourage expulsion of air as the pipe is being filled with water. Adequate air release
mechanisms should be located at all high points along the line.
• Before filling the pipeline, all line valves and air venting systems should be checked
open. All air must be removed from the system.
• Fill the system slowly. Water velocity must not exceed 0.6 m/s. Potable water pipelines
should be tested with potable water only. After charging, close all air valves and check
proper action of automatic valves.
• Allow the system to stabilize under a nominal pressure for a minimum of 2 hours.
Apply pressure steadily. Observe pressure gauges throughout and record the rates of
pressure increase.
• The pressure should be increased till the specified pressure is reached at the lowest part
of the section. Maintain test pressure at this level, by additional pumping if necessary,
for a period of 1 hour.
• Close all valves and disconnect the pressurizing unit. No further water should be
allowed to enter the system for a further period of 1 hour.
connections.
• If there has been a decrease in pressure during this period other than due to leakage, the
original pressure is re-established by injecting a measured quantity of water into the
section.
• there is no decrease in pressure (a slight rise in pressure is also, possible due to changes
in ambient temperatures),
• the measured quantity of water required to reinstate the pressure to the original test
pressure is less than the ‘permissible maximum’ Q,
• Where, Q = 4.5 liters per 1.6 km per 25 mm of nominal bore per 30 m head of test
• On completion of any test, the residual pressure should be released slowly and in a
carefully controlled manner.
• All defects revealed in the test should be rectified and the procedure repeated until a
satisfactory result is obtained.
641
• If any leakage is found during testing of pipeline, Contractor will have to attend the
same immediately and rectify at his cost. If Contractor fails to rectify the defect, the
entire length of pipeline between two adjacent outlets shall be rejected. If any
intermediate payment is made to the Contractor for portion under rejection, the same
shall be recovered from the outstanding dues of the Contractor.
PMC/TPI/QC. Modalities of PMC/TPI/QC Inspection shall be separately decided and
given by Engineer-In-charge.
• Measurement
The Hydraulic Testing of pipes as laid or fixed shall be measured in Kilomoters correct
to a metre. Specials shall be excluded and measured in running meters or numbers as
• Payment
shall be as under:-
• 80% of the payment will be released after supplying, lowering, laying, jointing and third
respective WUAs.

• After Successful Operation and Maintenance for Second year-2%
• After Successful Operation and Maintenance for Third year-2%
• After Successful Operation and Maintenance for Fourth year-2%
• After Successful Operation and Maintenance for Fifth year-2%

----------***----------
• Note
• The contractor shall operate and maintain the complete pipe distribution network for
the period of 5 (five) years after commissioning. Out of this period, during last two
642
years the operation of the schemes shall be done by the contractor jointly along with
WUA. On completion of O & M period, the system shall be handed over to WUA
• During rotation period, once in every year, the Contractor shall perform hydraulic
test to the satisfaction of Engineer In-charge to verify the flow of designed discharge,
detect or confirm any leakage in the system and rectify at his own cost. The testing
shall preferably be conducted jointly with members of WUA/representative of Engineer
In-charge, technical representative of contractor and any other stake holder.
• On completion of every Irrigation season, the contractor shall flush the pipe line from
its tail flush valve so that any siltation, vegetation or obstruction is cleaned and pipe is
able to flow designed discharge for next season.
• During the O & M period, contractor shall give training to the members of WUA about
O & M of PDN work and its efficient use and protection of the system from any
damages.
• The contractor shall prepare a detail map of the permanent marking along the alignment
of pipe and submit the same to Engineer In-charge. The Engineer In-charge shall verify
and endorse the location of the marking and handover these signed maps as a permanent
record to WUA. Along with this, the detailed Geotagged map of laid pipeline shall also
be handed over to WUA.
• In association of the members of WUA, the Engineer In-charge shall confirm the
release of designed discharge through every outlet before handing over. In case of any
short fall or defect, it should be made good from the contractor at his own cost.
643
SPECIFICATION FOR ORIENTED UNPLASTICIZED POLYVINYL CHLORIDE
PIPE (PVC-O)
12.24 Providing and supplying in ISI mark rigid PVC-O class-500 s/s pipes
( Item No. LIPDN 33)

Providing and supplying in ISI mark rigid PVC-O class-500 s/s pipes (push on
joints) pressure pipes confirming to IS specifications no 16647- 2017 inclusive cost of
EPDM gasket seals on joints including all statutory duties excluding GST levied by
Government of India and Government of Maharashtra in all respect including third
party inspection charges of agency approved by WRD, transit insurance loading,
unloading charges conveyance to the departmental store / site and stacking the same in
closed shade duly protected from sunrays etc. complete.
This specification covers the requirements for providing and supplying in ISI mark rigid
PVC-O class-500 s/s pipes (push on joints) pressure pipes confirming to IS
specifications no 16647- 2017 inclusive cost of EPDM gasket seals on joints including
all statutory duties excluding GST levied by Government of India and Government of
Maharashtra in all respect including third party inspection charges of agency approved
by WRD, transit insurance loading, unloading charges conveyance to the departmental
store / site and stacking the same in closed shade duly protected from sunrays etc.
complete. the manufacturer should have ISO-9001 certification for designing and
manufacturing. A copy of the valid ISO-9002 or ISO-9001 certificate acquired by the
manufacturer must be attached with every consignment dispatched to the site store.

• Introduction
Technology for manufacturing pipes, which involves process of controlled
circumferential and axial orientation of molecular structure resulting in formation of
laminar structure of the material used in the pipe construction, is commonly known
as PVC-O (Polyvinyl Chloride - Oriented). Manufacturing of pipes by this
technology increases performance and strength of pipes.
The Contractor shall provide onsite training on PVC-O pipe laying, jointing, testing
and maintenance etc., to the personnel authorized by the Engineer-in-charge. The
contractor should provide technical Manual on PVC-O pipes including precautions to
be taken during operation of the pipeline.
The manufacturing, testing, supplying, laying, jointing and testing at work sites of
PVC-O pipes shall comply with all currently applicable statutes, regulations, standards
and Codes. In particular, the following standards, unless otherwise specified herein,
shall be referred. In all cases, the latest revision of the Codes shall be referred to. If
mentioned here but pertaining to the use of PVC-O Pipes form part of these
Specifications.
644
IS- 4985 Unplasticized PVC pipes for potable water supplies
IS - 5382 Rubber Sealing rings for gas mains, Water mains and Sewers
IS - 7634 Laying and jointing of UPVC pipes
(Part-3)
IS-10151 Specification for polyvinylchloride (PVC) & its copolymers for its safe
use in contact with foodstuffs pharmaceuticals& drinking water.
IS - 16462 Plastic piping and ducting systems- Determination of the long term
hydrostatic strength of thermoplastics materials in pipe form by
extrapolation
IS - 16647 Oriented Unplastized Polyvinyl Chloride (PVC-O) pipes for water
supply.
• Raw Material
• Material
The Material from which the pipe is produced shall consist substantially of
unplasticized polyvinyl chloride to which may be added only those additives that
are needed to facilitate the manufacture of the pipe and the production of sound and
durable pipe of good surface finish, mechanical strength and opacity under
conditions of use. None of these additives shall be used separately or together in
quantities sufficient to constitute a toxic organoleptic or microbial growth hazard.
• Rework Material
The use of the manufacturer`s own reprocessed material produced during the
manufacture and works testing of products and conforming to the material
requirements of this standard is permitted. Reprocessed or recycled material
obtained from external sources shall not be used.
• VCM content
The monomer content (VCM content) in the resin shall be within the limits
• K-value
The composition shall be based on PVC resin having a K-value of 64 or great when
tested in accordance with IS 4669.
• Density
When determined in accordance with IS 12235, the density of the pipe
shall be between 1.40 g/cc and 1.46 g/cc.
• Material Classification
Based on the minimum required strength (MRS) values, the material shall be
classified in accordance with following Table No. 1
Table No. 1 Material Classification
645
Design Coefficient and Design Stress
Sr Minimum Pipe Material Design Design

NO Required Classification Coefficient, Stress,
Strength (MRS) Number
C σ = MRS/C
(Mpa)
(Mpa)
<1.4 32
I 45.0 450
1.6 28
<1.4 36
II 50.0 500
1.6 31

Manufacturing of PVC-O pipes involve process of controlled circumferential and
axial orientation of molecular structure resulting in formation of laminar structure of
the material used in the pipe construction.
• Classification of pipes:
The pipes shall be classified by their pressure ratings (Nominal pressures) (PN)
at 27oC and their material class classification and design coefficient as per
following Table No. 2
Table No. 2 Pressure Rating and Working Pressure of Pipes
Sr. Design
No. Coefficient, Pressure Rating (PN)
C
I - For Material Classification- Class 450
a) 1.4 PN -- PN -- PN -- PN -- PN --
10 12.5 16 20 25
b) 1.6 -- PN -- PN -- PN -- PN -- PN
10 12.5 16 20 25
II - For Material Classification- Class 500
a) 1.4 -- PN -- PN -- PN -- PN -- --
12.5 16 20 25
b) 1.6 PN -- PN -- PN -- PN -- PN --
10 12.5 16 20 25
Working pressure corresponding to various pressure ratings-
Pressure Ratings Working Pressure
PN 10 1.0 Mpa (10 kg/ cm2)
646
PN 12.5 1.25 Mpa(1.25 kg/
cm2)
PN 16 1.6 Mpa (16 kg/ cm2)
PN 20 2.0 Mpa (20 kg/ cm2)
PN 25 2.5 Mpa (25 kg/ cm2)

All PVC-O pipes in a single consignment of the same grade, same nominal pressure, same
size and manufactured under essentially similar conditions shall constitute a lot. The number
of test samples to be taken from a lot shall depend on the size of the lot, outside diameter of
the pipe and type of test as given in IS 16647.
• Visual and Dimensional Requirement
The number of test samples to be taken from a lot shall depend on the size of the lot
and the outside diameter of the pipes, and shall be in accordance with following Table
No.3
Table No. 3
Scale of Sampling for Visual Appearance, Colour and Dimensional Requirement
Sr. Number of Sample Sample Cumulative Acceptance Rejection
No. Pipes in a No. Size Sample Size No. No.
Lot
(1) (2) (3) (4) (5) (6) (7)
I Upto 1000 First 13 13 0 2
Second 13 26 1 2
II 1000 to First 20 20 0 2
3000
Second 20 40 1 2
III 3000 to First 32 32 0 3
10000
Second 32 64 3 4
IV 10001 and First 50 50 1 4
above
Second 50 100 4 5
• These pipes shall be selected at random from the lot.
• The number of pipes given for the first sample in Col.4 of Table No. 3 shall be taken
from the lot and examined for visual appearance, colour and dimensional requirement
given in point 6 below. A pipe failing to satisfy any of these requirement shall be
considered as defective. The lot shall be deemed to have satisfied these requirement, if
the number of defective found in the first sample is less than or equal to the
corresponding acceptance number given in Col no. 6 of Table No. 3. The lot shall be
deemed not to have met these requirements, if the number of defectives found in the
first sample is greater than or equal to the corresponding rejection number given in
Col.7 of Table No.3. If however the number of defectives found in the first sample lies
between the corresponding acceptance and rejection number given in Col 6 and Col 7,
a second sample of the size given in Col. 4 shall be taken and examined for these
requirements. The lot shall be considered to have satisfied these requirements, if the
647
number of defectives found in the cumulative sample is less than or equal to the
corresponding acceptance number given in Col. 6, otherwise not.
• Vicat Softening Test
• The lot having satisfied the requirement for visual appearance and colour and
dimensional requirement as per para 5.1, shall be tested for Vicat softening temperature.
The number of test samples to be taken from lot shall be as per following Table No.4
Table No 4
Scale of Sampling for Vicat Softening Temperature and Density Test.

Sr. Number Sample Sample Cumulative Acceptance Rejection

No. of Pipes Number Size Sample Number Number
in a Lot Size
(1) (2) (3) (4) (5) (6) (7)

i) For nominal outside diameter (dn) up to and including 110 mm
First 5 5 0 2
a) Upto
1000 Second 5 10 1 2
b) 1001 First 8 8 0 2
to
Second 8 16 1 2
3000
c) 3001 First 13 13 0 2
to
Second 13 26 1 2
10000
d) 10001 First 20 20 0 3
and
Second 20 40 3 4
above
ii) Fordnabove 110 mm
First 3 3 0 2
a) Upto
3000 Second 3 6 1 2
b) 3001 First 5 5 0 2
to
Second 5 10 1 2
10000
c) 10001 First 8 8 0 2
and
Second 8 16 1 2
above
• For this purpose, the number of pipes given for the first sample in Col No. 4 of Table
No.4 shall be taken from the lot. The sample pipe failing the Vicat softening test shall
be considered as defective. The lot shall be deemed to have met the requirement given
in this specification for the Vicat softening test. If the number of defectives found in
the first sample is less than or equal to the corresponding acceptance number given in
648
Col No. 6. The lot shall be deemed not to have met these requirements, if the number
of defectives found in the first sample is greater than or equal to the corresponding
rejection number given in Col No.6. If, however, the number of defectives in the first
sample lies between the corresponding acceptance and rejection numbers given in Col
No.6 and Col. 7 a second sample of size given in Col No.4 shall be taken and examined
for the requirement. The lot shall be considered to have satisfied the requirement, if the
number of defectives found in the cumulative sample is less than or equal to the
corresponding acceptance number given in Col No.6 otherwise not.
• Density
The lot having satisfied the requirement for visual appearance and colour and
dimensional requirement shall be tested for density. For this purpose, procedure
adopted for sampling and criteria for conformity shall be the same as that given in above
point and Table No.4.
• Resistance to External Blows at 0o C

The lot having been found satisfactory according to above para shall be tested for
resistance to external blows at 0o C. For this purpose, the procedure adopted for
sampling and criteria for conformity shall be as per following Table No. 5.
Table No 5 Scale of Sampling for Resistance to External Blows at 0°C

Sr Number of Sample Sample Cumulative Acceptance Rejection
No. Pipes in a Number Size Sample Number Number
Lot Size
(1) (2) (3) (4) (5) (6) (7)
First 3 3 0 2
Upto 3000
i)
Second 3 6 1 2
3001 to First 5 5 0 2
ii) 10000
Second 5 10 1 2
10001 and First 8 8 0 2

iii) above Second 8 16 1 2
NOTE – The numbers mentioned in col 4 to col 7 represent the number of times the
test is to be carried out and do not represent either the number of pipe samples or
number of blows or number of failures.
• Ring Stiffness Test

The Lot having satisfied the requirements for visual appearance and colour and
dimensional requirements as per para 5.1 shall be tested for requirements of ring
stiffness. The number of pipes to be taken from the lot shall depend on the size of
the lot and shall be according to following Table No. 6. If the first sample drawn
fails the test, resampling should be done from the lot which has satisfied the
dimensional and visual requirements. The lot shall be considered to have met the
requirements of these lots, of none of these samples tested fails.
649
Table No 6 Scale of Sampling for Ring Stiffness Test

Sr. Number of Pipes in a Lot Sample Size Sample Size
No. for Sizes Less for Sizes
than or Equal Greater
to 500 mm than 500
mm
Upto 1000 2 1
i)
1001 to 3000 3 2
ii)
3001 and above 4 3
iii)

Pipe selected as per sampling criteria mentioned in earlier para 5.0 are subject to
following tests before delivery from factory
1. Dimensions : Outside diameter, Wall thickness, Length of pipe

3. Colour
4. Opacity
5. Resistance to hydrostatic pressure
6. Resistance to external blows at 00 c
7. Ring Stiffness
8. Orientation Factor
9. Physical and Chemical Characteristics
These test shall be carried out by the agency in the presence of representative of
Engineer-in-charge/WRD/QC/TPI.
• Dimensions
• Outside Diameter: The Nominal outside diameter, outside diameter at any point
and their tolerances shall be as given in following Table No.7
Table No 7 Outside Diameter and Tolerances

Sr. Nominal Mean Outside Diameter, dem Outside Diameter at Any
No. Outside Point, dc
Diameter, dn Min Max Min Max
i) 63 63.0 63.3 62.2 63.8
ii) 75 75.0 75.3 74.8 75.9
iii) 90 90.0 90.3 88.9 91.1
iv) 110 110.0 110.4 108.6 111.4
v) 125 125.0 125.4 123.5 126.5
vi) 140 140.0 140.5 138.3 141.7
vii) 160 160.0 160.5 158.0 162.0
viii) 180 180.0 180.6 177.8 182.2
650
ix) 200 200.0 200.6 197.6 202.4
x) 225 225.0 225.7 222.3 227.7
xi) 250 250.0 250.8 242.0 253.0
xii) 280 280.0 280.9 276.6 283.4
xiii) 315 315.0 316.0 311.2 318.8
xiv) 355 355.0 356.1 350.7 359.3
xv) 400 400.0 401.2 395.2 404.8
xvi) 450 450.0 451.4 444.6 455.4
xvii) 500 500.0 501.5 494.0 506.0
xviii) 560 560.0 561.7 553.2 560.8
xix) 630 630.0 631.9 622.4 637.6
xx) 710 710.0 712.0 701.4 718.6
xxi) 800 800.0 802.0 790.4 809.6
xxii) 900 900.0 902.0 889.2 910.8
xxiii) 1000 1000.0 1002.0 988.0 1012.0
xxiv) 1200 1200.0 1202.0 1185.6 1214.4
• Wall Thickness: The wall thickness of the pipes shall confirm to values specified
in following Table No.8
651
Table No. 8 Wall thickness of the pipe
Wall Thickness, en (mm) for various pipe material classification and design stress coefficient (C)
Nominal Class 450/C = 1.4 Class 500/C = 1.4 Class 450/C = 1.6 Class 500/C = 1.6
Sr.
Diameter,
No. Nominal Pressure, PN Nominal Pressure, PN Nominal Pressure, PN Nominal Pressure, PN
dn (mm)
10 12.5 16 20 25 12.5 16 20 25 10 12.5 16 20 25 10 12.5 16 20 25
i) 63 1.1 1.3 1.7 2.1 2.6 1.2 1.5 1.8 2.3 1.2 1.5 1.8 2.3 2.9 1.1 1.3 1.7 2.1 2.6
ii) 75 1.3 1.6 2 2.4 3.1 1.4 1.8 2.2 2.7 1.4 1.8 2.2 2.7 3.4 1.3 1.6 2 2.4 3.1
iii) 90 1.5 1.9 2.4 2.9 3.7 1.7 2.1 2.6 3.3 1.7 2.1 2.6 3.3 4.1 1.5 1.9 2.4 2.9 3.7
iv) 110 1.8 2.3 2.9 3.6 4.5 2 2.6 3.2 4 2 2.6 3.2 4 5 1.8 2.3 2.9 3.6 4.3
v) 125 2.1 2.6 3.3 4 5.1 2.3 2.9 3.6 4.5 2.3 2.9 3.6 4.5 5.6 2.1 2.6 3.3 4 5.1
vi) 140 2.3 2.9 3.6 4.5 5.7 2.6 3.2 4 5.1 2.6 3.2 4 5.1 6.3 2.3 2.9 3.6 4.5 5.7
vii) 160 2.6 3.3 4.2 5.1 6.5 2.9 3.7 4.6 5.8 2.9 3.7 4.6 5.8 7.2 2.6 3.3 4.2 5.1 6.5
viii) 180 3 3.7 4.7 5.8 7.3 3.3 4.2 5.2 6.5 3.3 4.2 5.2 6.5 8.1 3 3.7 4.7 5.8 7.3
ix) 200 3.3 4.1 5.2 6.4 8.1 3.6 4.6 5.7 7.2 3.6 4.6 5.7 7.2 9 3.3 4.1 5.2 6.4 8.1
x) 225 3.7 4.6 5.8 7.2 9.1 4.1 5.2 6.4 8.1 4.1 5.2 6.4 8.1 10.1 3.7 4.6 5.8 7.2 9.1
xi) 250 4.3 5.1 6.5 8.6 10.2 4.5 5.8 7.2 9 4.5 5.8 7.2 9 11.2 4.1 5.1 6.5 8 10.2
652
xii) 280 4.6 5.7 7.2 9 11.4 5.1 6.4 8 10.1 5.1 6.4 8 10.1 12.5 4.6 5.7 7.2 9 11.4
xiii) 315 5.1 6.4 8.1 10.3 12.8 5.7 7.2 9 11.4 5.7 7.2 9 11.4 14.1 5.1 6.4 8.1 10.1 12.8
xiv) 355 5.8 7.2 9.2 11.4 14.4 6.4 8.2 10.1 12.8 6.4 8.2 10.1 12.8 15.9 5.8 7.2 9.2 11.4 14.4
xv) 400 6.5 8.1 10.3 12.8 16.2 7.2 9.2 11.4 14.4 7.2 9.2 11.4 14.4 17.9 6.5 8.1 10.3 12.8 16.2
xvi) 450 7.4 9.3 11.6 14.4 18.2 8.3 10.3 12.8 16.2 8.3 10.3 12.8 16.2 20.1 7.4 9.3 11.6 14.4 18.2
xvii
500 8.2 10.9 12.9 16 20.3 9.2 11.4 14.2 18 9.2 11.4 14.2 18 22.3 8.2 10.4 12.9 16 20.3
)
xviii
560 9.2 11.6 14.4 17 23.7 10.3 12.8 15.9 20.2 10.3 12.8 15.9 20.2 25 9.2 11.6 14.4 17.9 22.7
)
xix) 630 10.3 13 16.2 20.1 25.5 11.6 14.4 17.9 22.7 11.6 14.4 17.9 22.7 28.1 10.3 13 16.2 20.1 25.5
xx) 710 11.6 14.7 18.3 22.7 28.7 13.1 16.2 20.2 25.6 13.1 16.2 20.2 25.6 31.7 11.6 14.7 18.3 22.7 28.7
xxi) 800 13.1 16.5 20.6 25.5 32.4 14.7 18.3 22.7 28.8 14.7 18.3 22.7 28.8 35.7 13.1 16.5 20.6 25.5 32.4
xxii
900 14.7 18.6 23.1 28.7 36.4 16.5 20.8 25.5 32.4 16.5 20.6 25.5 32.4 40.2 14.7 18.6 23.1 28.7 36.4
)
xxiii
1000 16.4 20.7 25.5 31.9 40.5 18.4 22.8 28.4 36 18.4 22.8 28.4 36 44.6 16.4 20.7 25.7 36.9 40.5
)
xxiv
1200 19.6 24.8 30.8 38.3 48.5 22 27.4 34 40.2 22 27.4 34 43.2 53.5 19.6 24.8 30.8 38.3 48.5
)
653
654
• Length: The pipe shall be supplied with the length not less than the declared nominal pipe
length. It is recommended that the nominal pipe length to be supplied may be 6m, 10m and
12m. The pipes may be supplied in other lengths where so agreed upon between the
manufacturer and the purchaser.
• Visual Appearance
When checked without magnification glass, the internal and external surfaces of the pipe
shall be smooth, clean and free from scoring, cavities and other surface defects. Slight
shallow longitudinal grooves or irregularities in the pipe shall be permissible provided the
wall thickness remains within the permissible limits. The material shall not contain visible
impurities. The ends of the pipe shall be either cut cleanly and reasonably square to the axis
of the pipe or chamfered at the plain end at approximately 15o to the axis of the pipe.
• Colour
The colour of the pipe shall be any shade of grey, blue or cream. The pipe may also be
supplied in any other colour as agreed to between the manufacturer and the supplier. Slight
variations in the appearance of the colour may be permitted.
• Opacity
The wall of the pipe shall not transmit more than 0.2 % of the visible light falling on it when
tested in accordance with IS 12235
• Resistance to hydrostatic pressure

Resistance to hydrostatic pressure shall be verified using the induced stresses derived from
the analysis of the test data in accordance with IS 16462. For a period of 10 h at 270 C and
1000 h at 270 C, the 99.5 percent LPL value shall be taken as the minimum stress level.
For a period of 1000 h at 600 C, the 99.5 percent LPL value established from analysis of test
data at 600 C in accordance with IS 16462 can be taken as the minimum stress level. In case
of lack of data, alternatively, a value of 0.625 times the MRS (Minimum Required Strength)
value shall be taken as the minimum stress level.
When tested in accordance with IS 12235, the pipe shall not fail in less than the times stated
above. The test shall be carried out not earlier than 24 h after the pipes have been manufacture
• Resistance to external blows at 00 C
Pipes when tested at00 C in accordance with IS 12235 using striker mass as given in Col 3
of following Table No. 9 and drop height for various nominal sizes as per Col 4 of Table No.
9, shall have a true impact rate (TIR) of not more than 10 percent. In case of socket ended
pipes, this test shall be carried out on the plain portion of the pipes taken at least 100mm
away from the route of the socket.
655
Table No 9 Classified Striker Mass and Drop Height Conditions for the Falling Weight Impact
Test
Sr. Nominal Diameter, Total Mass Drop Height
No. dn
(kg) (mm)
(mm)
i) 63 4 2.0
ii) 75 5 2.0
iii) 90 5 2.0
iv) 110 6.3 2.0
v) 125 6.3 2.0
vi) 140 8 2.0
vii) 160 8 2.0
viii) 180 10 2.0
ix) 200 10 2.0
x) ≥ 225 12.5 2.0
NOTE - Impact characteristics can change over time. These values are
applicable only at the time of manufacture.
• Ring Stiffness
The minimum value of ring stiffness of pipe when determined in accordance with IS 12235
shall be as specified in following Table No. 10
656
Table No.10 Ring Stiffness of Pipes.
Sr. Nominal Ring Stiffness Ring Stiffness

No. Diameter, dn
(KN/m2) (For Specific Jointing
(mm) Techniques)
(KN/m2)
(1) (2) (3) (4)

i) 63 ≥ 20
ii) 75 ≥6 ≥ 12
iii) 90 ≥ 10
iv) 110 ≥ 10
v) 125 ≥8
vi) 140 ≥4 ≥7
vii) 160 ≥7
viii) ≥ 200 ≥6
• Pipes of stiffness less than 4 KN/m2 might not be suitable where high vacuum
or external pressure could be developed and could need special installation
techniques where installed below ground.
• Due to specific jointing techniques in water supply and installation below
ground, higher stiffness may be needed.
• Orientation Factor
The determination of the stretch ratios (axial orientation factor and circumferential factor)
shall be carried out as per procedure mentioned in Annexure-E of IS 16647.
• Physical and Chemical Characteristics

When tested in accordance with the methods as specified in following Table No. 11 using
the parameters indicated therein, the pipe shall have Physical and Chemical Characteristics
conforming to the requirement given in following Table No. 11
657
Table No 11 Physical and Chemical Characteristics.

Sr. Characteristic Requirement Test Parameters Test Method, Ref
No. in
(1) (2) (3) (4) (5)

i) Vicat Softening ≥ 80°C Shall confirm to IS 12235 IS 12235 (Part 2)
temperature (Part 2) and
Number of test pieces = 3
ii) Effect on water As per IS 4985 IS 12235 (Part 4) and IS IS 12235 (Part 4)
12235 (Part 10) and IS 12235
(Part 10)
iii) Resistance to Di- No attack at any Temperature of bath- 15°C IS 12235 (Part 11)
chloromethane at a part of the surface ±5°C
specific of the test piece
temperature Immersion time- 15 min
(Degree of and
gelation) minimum wall thickness –
1.5 mm
iv) Alternative test to Minimum stress 48 In accordance with IS IS 12235 (Part 13)
resistance to di- MPa 12235 (Part 13)
chloromethane test
Uni-axial tensile
test
Each pipe shall be indelibly marked in English language at intervals of not more than 1 m.
The marking shall show the following.

2. Pipe material and material classification Number
3. Outside diameter
4. Nominal pressure
9. Any other important matter that the manufacturer or purchaser deems fit
to be inscribed.
658
• Transportation of Pipes
As PVC-O pipes are durable and light, they are more likely to be mishandled. Following
precautions shall be taken during transportation of pipes.
• When transporting pipes, flat bed vehicles should be used. The bed should be free from
nails and other projections. When practical, pipes should rest uniformly on the vehicle
over the whole length.
• The vehicles should have side supports approximately 2 m apart and the pipes should
be secured effectively during transport. All posts should be flat with no sharp edges.
• When loading spigot and socket pipes, the pipes should be stacked on the vehicle so that
the socket do not take excessive loads.
• Where pipes overhang the vehicle, the amount of overhang should not exceed 1 m.
• High stiffness pipes should be placed at the bottom of the load and low stiffness pipes
at the top.
• Care should be taken to avoid positioning the pipes near to any exhaust systems or any
other potential hazards such as diesel oil, paints or solvents.
• When pipes are transported in bundles, the bundles should be secured effectively and
off- loaded with due care.
• Mechanical lifting equipment used for lifting pipes and pipe bundles should not damage
the pipe. Fork-lift forks should be flat and protected. Cranes should have spreader bars.
No wire ropes, chains or hooks should be used. Slings should be made of rope or
webbing 7 to 10 cm wide.
• If pipes have been telescoped for transporting, the inner pipes should be removed first
and stacked separately.
• Stacking of Pipes
Following precautions shall be taken so as to eliminate potential damage to pipes
• Store the pipes horizontallyon a flat surface and place supports every 1.5 m to avoid the
bending of the pipe.
• Avoid scratches especially in the crest of the socket, due to dragging the pipe on the
ground, mainly if the surface is made of stone, concrete or asphalt.
• Do not stack pipes more than 1.5 m height, as this can damage lower pipes or even the
upper pipes can fall.
• The sockets should be free, alternating sockets and ends.
• In case of prolonged sun exposure, protect pallets with an opaque material. White colour
is preferable because it avoids the over heating of pipes.
• Valves
For PDN work, various Valves as mentioned below are required to be provided on pipeline at
various locations.
• Air Valve :
firstly, in the water filled stage of the pipeline, filled with water by a certain velocity, the
air valve can discharge the remained gas in the pipe; secondly, at the normal working
stage, the air valve can discharge the small amount of gas gathered in the pipe timely;
659
finally, during the pump failure or maintenance stages, the air valve will replenish the gas
into the pipe to break the vacuum. According to the orifice size, displacement and work
pressure, air valve is divided into high pressure trace exhaust valve, low pressure air
release valve and combined air valve.
• Scour Valve :
pipeline crosses a stream or drainage structures, there will usually be a low point in the
line but if the main pipeline goes under the stream or drain, it cannot be completely
drained into the channel. In such a situation it is better to locate a scour connection at the
lowest point that will drain by gravity and provide for pumping out the part below the
drain pipeline.
• Control Valve :
G) Sliding Stem
• Globe valve
H) Rotary
• Butterfly valve
• Ball valve
I) Other
• Pinch valve
• Diaphragm valve

After delivery of pipes to worksite, additional test, if desired by Engineer-in-charge shall be
conducted on random samples of pipes collected from site. These test shall be as per those
given in forgoing para No.6.0

• Work of PDN shall be inspected, tested and certified by PMC / TPI / QC. Modalities of
PMC / TPI / QC Inspection shall be separately decided and given by Engineer In-charge.
Project management consultants (PMC) should have approved laboratories certification
or collaboration with N.A.B.L. (National Accreditation Board for Testing and
Calibration Laboratories)
660

3 S.G.S, Mumbai
5 VJTI, Mumbai
(e) All materials before being utilized in works shall be inspected and tested, by the
by the contractors.
(f) The materials shall be tested in QC laboratory or at any other place directed by the
be carried out as aforesaid so that he may satisfy himself regarding the procedure and
work, materials and finished item to the standard as determined by the laboratory
tests or to take follow up action to rectify the quality.
(g)Testing charges for testing of Cement, TMT bars, all types of pipes and specials
(h)The Contractor shall make suitable arrangements to see that one of his representatives

661
Quality Assurance.

2 Laboratory Assistants(Twevlth Pass with Two to Four

of material) (As per work)
(One for each L.A.)


for Sand & Metal.

mortar, concrete, sand, coarse aggregates etc. shall be carried out in field laboratory set
up by the contractor in presence of quality control representative at contractors cost.
662
specification.
work.

• Pre delivery testing of pipes shall be carried out by the contractor in the presence of
representative of Engineer-In-charge /WRD/QC/TPI. like Dimensions : Outside
diameter, Wall thickness, Length of pipe, Visual appearance Colour Opacity Resistance
to hydrostatic pressure, Resistance to external blows at 00 c , Ring Stiffness, Orientation
Factor, Physical and Chemical Characteristics .
• When transporting pipes, flat bed vehicles should be used. The bed should be free
from nails and other projections. When practical, pipes should rest uniformly on the
vehicle over the whole length.
• The vehicles should have side supports approximately 2 m apart and the pipes should
be secured effectively during transport. All posts should be flat with no sharp edges.
• When loading spigot and socket pipes, the pipes should be stacked on the vehicle so that
the socket do not take excessive loads.
• Where pipes overhang the vehicle, the amount of overhang should not exceed 1 m.
• High stiffness pipes should be placed at the bottom of the load and low stiffness pipes
at the top.
• Care should be taken to avoid positioning the pipes near to any exhaust systems or any
other potential hazards such as diesel oil, paints or solvents.
• When pipes are transported in bundles, the bundles should be secured effectively and
off- loaded with due care.
• Mechanical lifting equipment used for lifting pipes and pipe bundles should not damage
the pipe. Fork-lift forks should be flat and protected. Cranes should have spreader bars.
No wire ropes, chains or hooks should be used. Slings should be made of rope or
webbing 7 to 10 cm wide.
• If pipes have been telescoped for transporting, the inner pipes should be removed first
and stacked separately.
• Store the pipes horizontally on a flat surface and place supports every 1.5 m to avoid
the bending of the pipe.
• Avoid scratches especially in the crest of the socket, due to dragging the pipe on the
ground, mainly if the surface is made of stone, concrete or asphalt.
663
• Do not stack pipes more than 1.5 m height, as this can damage lower pipes or even the
upper pipes can fall.
• The sockets should be free, alternating sockets and ends.
• In case of prolonged sun exposure, protect pallets with an opaque material. White colour
is preferable because it avoids the over heating of pipes.
suitably and neatly along the alignment/road side/elsewhere near by the work site or
as directed by the Engineer-in-Charge.
• After delivery of pipes to worksite, additional test, if desired by Engineer-in-charge,

Measurement
• The net length of pipes as laid or fixed shall be measured in running meters correct to a
cm. Specials shall be excluded and measured in running meters or numbers as specified
by Engineer-in-charge and paid for separately under the relevant item. The portion of
the pipe overlapped at the joints shall not be included in the length of pipe work.
Excavation, refilling, anchor blocks, thrust blocks wherever required shall be measured
and paid for separately under relevant items of work

• Payment
shall be as under:-
of respective WUAs.

664
----------***----------
665
12.25 Lowering, laying and jointing with P.V.C.-O pipes and specials
(Item No. LIPDN 34)
Lowering, laying and jointing with P.V.C.-O pipes and specials of following class and
diameter including cost of conveyance from stores to site of works including cost of all labour,
material, except cement solvent, rubber ring, as per IS code, for all class of pipe, etc. complete
(with cement solvent joint / ring fit joint).

testing at works and site of Oriented Unplasticized Polyvinyl Chloride (PVC-O) Pipes
conforming to I.S. 16647:2017 including cost of all labour, material, except cement solvent,
rubber ring, as per IS code, for all class of pipe, etc. complete (with cement solvent joint / ring
fit joint).

brushwood, rubbish of all kinds, loose stones and all other objectionable materials shall
be removed by the Contractor. Buried irrigation pipeline, and other structure, if any, shall
be removed by the Contractor. The ownership of all the usable material, so removed from
clearing site and/or excavation shall rest with the Engineer In-charge. Useful material
shall be stacked as directed. The Contractor shall dispose off all un-useful materials as
directed by the Engineer In-charge.
• Demarcation
The centre line of excavation shall be clearly marked by pegs or by stones at each chain
or change of direction or at shorter intervals on curves, in the beginning. The final line
out will be done by fixing reference stone at suitable distances on either side of the centre
line, beyond the canal edges so that they are not disturbed during the construction period.
The position of these stones will be marked on the cross section.

(a) Benchmarks fixed by the Survey of India and temporary benchmarks established by the
Engineer In-charge in vicinity of PDN work will serve as control points for these works.
The Contractor shall establish sufficient number of reference benchmarks for
(b) Before starting any work, the Contractor shall erect reference benchmarks, reference
666
benchmark.
(d) All materials, labour and equipments (theodolites, levels, distometre, etc.) for setting
Contractor.
3. Levels 2Nos.
4. Staves 4Nos.
All equipments shall be of standard and approved make and precision, and shall be
made available in advance of starting of the work. All equipment shall be maintained,
repaired and got tested and certified as and when required for its accuracy from the
standard test houses or from the manufactures and to the satisfaction of the Engineer-
In-Charge.

• Excavation of pipe trenches shall be carried out as per excavation line shown in the
drawing or as directed by Engineer In -charge. Contractor must assume all responsibility
for deductions and conclusion made by him as to the nature of the materials to be
excavated and the difficulties of making and maintaining the required excavation. The
trench width at bottom shall be 300 mm more than 1.5 times outside pipe diameter. In
any case trench width shall not be less than 500 mm.
• The usable excavated material available from the excavated trenches (PDN) shall be
used in backfilling. If such usable material is in excess of the requirement of backfilling,
the same shall be deposited in the spoils as and where directed by the Engineer In-
charge. Un-useful material from excavation shall be deposited in spoils as and where
directed by Engineer-In-charge.
667
trench. When the drain/nalla bed is higher than the sub-soil water level met with, the
bailing out by suitable means of pumping shall be resorted to for dewatering sub-soil
water below the drain/nalla bed level. No distinction shall be made as to whether the
material being excavated is dry, moist, wet or slushy. The Contractor shall have to
excavate the PDN pipe trench and structure in under water level conditions also i.e.
under wet/slushy condition after providing sufficient arrangement of dewatering. The
material excavated under water level condition which requires intermediate stacking for
drying shall have to be re-handled. No extra payment for efforts for drying out of soil,
re-handling of dry soil, etc. shall be given. No payment for extra efforts for excavation
under this condition shall be made.
• Over excavation performed by the Contractor for any purpose or reason, except for
additional excavation as may be directed by the Engineer-In-charge, shall be rectified
at the cost of the Contractor. Filling and compaction for such over excavation using the
material as directed by the Engineer in- Charge shall also be at the cost of the Contractor.
• In the PDN and structure section where expansive type of the soil such as CH type of
soil is encountered and over which PDN cannot be directly laid, the PDN trench and
structure shall be over excavated to the extent as directed by the Engineer In Charge and
such over excavated section shall be filled with suitable murum type soil to be placed
in uniformly compacted layers as directed by the Engineer In Charge. The over
excavation made in such strata, filling by suitable soil, and watering and compacting
such soil will be paid separately under relevant items. Above provision for over
excavating and filling with suitable murum type or good soil available material shall be
applicable in case such treatment is found essential.
• Laying of Pipes
While laying of PVC-O pipes, all precautions as mentioned in IS 7634 (Part-3) shall
be taken.
• Each pipe shall be thoroughly checked for any damages before laying and only pipes
that are approved by Engineer-in-Charge shall be laid.
• The trench bottom shall be constructed to provide a firm, stable and uniform support
for the full length of the pipeline. There should be no sharp objects that may cause
point loading.
• A minimum bedding thickness of 100 to 150 mm under the pipe shall be provided by
watering and compaction
• For pipes of diameter 100 mm or greater, bell holes in the bedding , under each socket
joint, shall be provided by removing some of the bedding material, to accommodate
the larger diameter of the joint and to permit the joint to be made properly.
• The pipes shall be preferably laid with the spigots entered into the sockets in the same
direction as the intended flow of water.
provided at all changes of direction, tees, blank ends, large reductions in diameter and
valves.
• Metal marker tape can be laid into the final backfill to enable electronic location of the
pipe line, if required.
• Jointing of pipes shall be carried out as per following procedure.
g) Lubricate the chamfer of the spigot and the seal with joint lubricant.
668
h) Line up the pipe as much as possible horizontal and vertically.
i) Insert only the chamfer edge of the socket, just to support the pipe but leaving the
socket lip free.
j) In case of pipes with nominal daimeter ≤ 250 mm, a firm and dry push should be given
to seize the momentum produced by the free movement in the lip of the socket and
introduce it until the mark is hidden into the socket.
k) When installing pipes with diameters > 250 mm, one should use mechanical means to
introduce the pipe using materials such as woods, hoists, tackles or slings.
l) The joint shall fulfill the following criteria
m) Short-Term Pressure Test for Leak Tightness of Assemblies

When an assembly with one or more elastomeric sealing ring type joints is tested using a
hydrostatic pressure and angular deflection in accordance with IS 12235 and the test
conditions given in following Table No.12,the assembly shall conform to the requirement
given in Table No.12.
Table No 12 Test Conditions and Requirements for Short-Term Assembly Test.
Sr. Test Temperature °C Test Pressure Test Time Test

No. requirement
(MPa) (min)
No leakage
at any point
T±2 Pressure
of the
calculated in One cycle in
(where T is any accordance with jointing
accordance with
i) areas
temperature between fig.2 and para fig.2 of IS 16647
20°C and 27°C) throughout
11.2.2 of IS 16647
the whole
test cycle
NOTE - The pressure changes from one pressure level to the next shall take place within
the periods indicated, but need not take place at strictly linear rates.
• Short-Term Negative Pressure Test for Leak Tightness of Assemblies

When an assembly with one or more elastomeric sealing ring type joints is tested using
negative pressure with angular deflection and deformation in accordance with IS 12235
and the test conditions given in following Table No.13, the assembly shall conform to the
requirement given in Table No.13. Procedure for calculating negative pressure capability
of pipes for different class and design coefficient is as given in Annex 1 of IS 16647.
669
Table No 13 Test conditions and Requirements for Short-Term Negative-Pressure Assembly
Test.
Sr. Test Test Pressure Test Time Test
No. Temperature requirement
°C (MPa) (min)
i) The change in
T±2 negative
pressure shall
(where T is Pressure calculated One cycle in be not more
any in accordance with accordance with than 0.005 MPa
temperature fig.3 of IS 16647 fig.3 of IS 16647 during each 15
between 20°C min test period
and 27°C) shown in fig.3
of IS 16647
NOTES –
1. The pressure change from one pressure level to the next, need not take place at
strictly linear rates.
2. For pipes with integral sockets, there is no need for testing with angular
deflection.
3. For pipes of ring stiffness less than 4 KN/m 2,it is allowed to support the pipe to
avoid collapsing during testing.
• Long-Term Negative Pressure Test for Leak Tightness of Assemblies
When an assembly with one or more joints selected from elastomeric sealing ring type
sockets and other end-loaded-bearing and non-end-load- bearing joints for oriented PVC-
U components for a piping system is tested in accordance with IS 12235 using the test
conditions given in following Table No. 14 for the test temperatures of 27 o C and 40o C,
the assembly shall conform to the requirements given in Table No. 14
Table No. 14 Test Requirements for Long-Term Pressure Testing of Assembled Joints.
Sr. No. Test Test Pressure Test Time Test requirement
Temperature
°C (MPa) (hr)
27 1.3 PN 1000 No leakage at any

i)
point of the
jointing areas at
40 1.1 PN 1000 least for the test
ii)
time
Note :The PN rating to be taken to calculate the test pressure shall be the PN rating
of the fitting and if pipe with an integral joint is being tested, it shall be the PN rating
of the pipe.
670
• Elastomeric Seals
Elastomeric Sealsused for jointing components shall conform to both the following
requirements.
• Rings shall conform to the material requirements specified in IS 5382
• Rings shall be free from chemical agents such as plasticizers that could have a
detrimental effect on the pipes or fitting or on the quality of the water.
(a) The type of material used for backfilling and the manner of depositing the material, shall
be subject to approval by the Engineer-in-Charge.
(b) The backfill material shall be placed to the line and grades as shown on drawings or as
(c) The backfill material shall be placed carefully and spread in uniform
layers of not more than 15cm thickness, with the first layer watered and compacted by
stamping or by mechanical means. The backfill shall be brought up as uniformly as
(d) Only soft earth and gravel of good quality free from boulder, roots,
vegetable matters etc. shall be used for refilling of trench up to 300mm above the top of
the pipe. If sufficient quantity of suitable (Sharp edge stone free) excavated earth is not
available, the trench shall be filled by borrowed gravel material up to 300 mm above top
of pipeline. Remaining trench can be filled with available material.
(e) When compacting the soil against steep rock, abutment walls of
concrete structures, rollers shall not be used close to structures as structural damage is
very likely more particularly when structures have not been fully cured. The size and
weight of equipment will depend on nature of material, the height and load assumed in
design of structure. The backfill close to the structure up to the rolled layer shall be
compacted in suitable uniform layers, using pneumatic / hand tampers as appropriate
for dry density at average bulk density (+/- 10%). The moisture content of the earth fill
placed against the rock or the structure shall be on higher/lower side of OMC by about
2% or so, to allow it to be compacted. Profuse watering shall be done to pervious
materials (sand) before compaction as per instruction of the Engineer-in-Charge.
Compaction at junction of earthwork and backfill around the structure shall be carried
out with special care.
farmers.
(15x15x45)CM embedded in concrete block of size (30x30x30)CM. The base of this
block shall be buried in ground projecting only 15cm above the ground and the base
concrete block.
• These blocks shall be able to locate the pipeline as and where it is laid all over the
671
period of the contract. Any damage done to these blocks for the reasons whatsoever
shall be made good at the cost of contractor.
• The contractor shall submit the location of such blocks with specific identification
• The map of marking of the block shall be handed over to WUA while handing over
the command area.

3 S.G.S, Mumbai
4 Vishveshvariaya National Institute of Technology, Nagpur
5 VJTI, Mumbai
A) All materials before being utilized in works shall be inspected and tested, by the
by the contractors.
672
B) The materials shall be tested in QC laboratory or at any other place directed by the
C) Testing charges for testing of Cement, TMT bars, all types of pipes and specials
D) The Contractor shall make suitable arrangements to see that one of his representatives


2 Laboratory Assistants (Twevlth Pass with Two to Four

(One for each L.A.)

673

for Sand & Metal.

specification.
work.

• The Contractor shall clear the entire area required for setting out. All tree stumps, roots,
brushwood, rubbish of all kinds, loose stones and all other objectionable materials shall
be removed by the Contractor.
• All materials such as pegs, bamboo’s and strings and templets for marking out slopes,
and labour required for lineout should be provided by the Contractor at his own cost.
• The center line of excavation shall be clearly marked by pegs or by stones at each chain
or change of direction or at shorter intervals on curves, in the beginning. The final
674
lineout will be done by fixing references to neat suitable distances on either side of the
center line, beyond the canal edges so that they are not disturbed during the construction
period.
• Prior permission of other department like P.W.D., H.P.C.L, M.J.P. shall be taken if the
alignment of pipe line crosses railway line, roads, gas pipe lines etc.
• Benchmarks fixed by the Survey of India and temporary benchmarks established by
the Engineer In-charge in vicinity of PDN work will serve as control points.
• Before starting any work, the Contractor shall erect reference benchmarks, reference
• All materials, labour and equipments (theodolites, levels, distometre, etc.) for setting
supplied by the Contractor at his cost.
drawing or as directed by Engineer In-charge.
• The usable excavated material available from the excavated trenches(PDN)shall be
used in backfilling. If such usable material is in excess of the requirement of
Engineer In-charge.
• In the PDN and structure section where expansive type of the soil such as CH type of
structure shall be over-excavated to the extent as directed by the Engineer In-Charge
and such over-excavated section shall be filled with suitable murum type soil to be
placed in uniformly compacted layers as directed by the Engineer In-Charge. The over-
excavation made in such strata, filling by suitable soil, and watering and compacting
such soil will be paid separately under relevant items. Above provision for over-
excavating and filling with suitable murum type or good soil available material shall
be applicable in case such treatment is found essential.
• Before the pipes are lowered and laid in position the contractor shall see that the invert
at the support is correct and pipe is brought to uniform grade and level. This should be
checked with the help of dumpy level and should be got approved in advance from
Engineer-in-charge.
• While laying of PVC-O pipes, all precautions as mentioned in IS 7634 (Part-3) shall
be taken.
drawings.
• Each pipe shall be thoroughly checked for any damages before laying and only pipes
that are approved by Engineer-in-Charge shall be laid.
• The trench bottom shall be constructed to provide a firm, stable and uniform support
for the full length of the pipeline. There should be no sharp objects that may cause
point loading.
• A minimum bedding thickness of 100 to 150 mm under the pipe shall be provided by
watering and compaction
• For pipes of diameter 100 mm or greater, bell holes in the bedding , under each socket
joint, shall be provided by removing some of the bedding material, to accommodate
the larger diameter of the joint and to permit the joint to be made properly.
• The pipes shall be preferably laid with the spigots entered into the sockets in the same
direction as the intended flow of water.
675
provided at all changes of direction, tees, blank ends, large reductions in diameter and
valves.
• Metal marker tape can be laid into the final backfill to enable electronic location of the
pipe line, if required.
• Jointing of pipes shall be carried out as per following procedure.
n) Lubricate the chamfer of the spigot and the seal with joint lubricant.
o) Line up the pipe as much as possible horizontal and vertically.
p) Insert only the chamfer edge of the socket, just to support the pipe but leaving the
socket lip free.
q) In case of pipes with nominal daimeter ≤ 250 mm, a firm and dry push should be given
to seize the momentum produced by the free movement in the lip of the socket and
introduce it until the mark is hidden into the socket.
r) When installing pipes with diameters > 250 mm, one should use mechanical means to
introduce the pipe using materials such as woods, hoists, tackles or slings.
s) The backfill material shall be placed to the line and grades as shown on drawings
or as prescribed in this paragraph or as directed by the Engineer-in-Charge.
t) The backfill material shall be placed carefully and spread in uniform
layers of not more than 15cm thickness, with the first layer watered and compacted by
stamping or by mechanical means. The backfill shall be brought up as uniformly as
u) The trench shall be refilled so as to built-up the original ground level.
• Compaction at junction of earthwork and backfill around the structure shall be carried
• The contractor shall establish the sufficient number of reference blocks for permanent
marking on the alignment of PDN preferably at the interval of 30m or as suitable on
the field boundaries so as they will not be disturbed during the agricultural activities of
the farmers.
v) For the desired quality of work. Whenever the testing of construction materials, pipes

• Measurement
The net length of lowering, laying & jointing of pipes as laid or fixed shall be measured
in running meters correct to a cm. Specials shall be excluded and measured in running
meters or numbers as specified by Engineer-in-charge and paid for separately under the
relevant item. The portion of the pipe overlapped at the joints shall not be included in
the length of pipe work. Excavation, refilling, anchor blocks, thrust blocks wherever
required shall be measured and paid for separately under relevant items of work.

shall be as under:-
676
of respective WUAs.

----------***----------
677
12.26 Providing and supplying ISI mark P.V.C.-O pipes fitting / specials ( Item
No. LIPDN 35)

Providing and supplying ISI mark P.V.C.-O pipes fitting / specials including loading,
unloading, transportation up to departmental store, stacking excluding GST levied by GOI &
GOM in all respect. etc. Complete.

This specification covers the requirements for providing and supplying ISI P.V.C.-O pipes
fitting / specials including loading, unloading, transportation up to departmental store,
stacking excluding GST levied by GOI & GOM .

• Introduction
• Technology for manufacturing pipes, which involves process of controlled
circumferential and axial orientation of molecular structure resulting in formation of
laminar structure of the material used in the pipe construction, is commonly known
as PVC-O (Polyvinyl Chloride - Oriented). Manufacturing of pipes by this technology
increases performance and strength of pipes.
13
• The Contractor shall provide onsite training on PVC-O pipe laying, jointing, testing
and maintenance etc., to the personnel authorized by the Engineer-in-charge. The
contractor should provide technical Manual on PVC-O pipes including precautions to
be taken during operation of the pipeline.
• The manufacturing, testing, supplying, laying, jointing and testing at work sites of PVC-
O pipes shall comply with all currently applicable statutes, regulations, standards and
referred. In all cases, the latest revision of the Codes shall be referred to. If requirements
of this Specification conflict with the requirements of the standards/Codes, this
Specification shall govern. Others Codes not specifically mentioned here but pertaining
to the use of PVC-O Pipes form part of these Specifications.
IS- 4985 Unplasticized PVC pipes for potable water supplies
IS - 5382 Rubber Sealing rings for gas mains, Water mains and Sewers
IS - 7634 Laying and jointing of UPVC pipes

(Part-3)
IS-10151 Specification for polyvinylchloride (PVC) & its copolymers for its safe
use in contact with foodstuffs pharmaceuticals& drinking water.
678
IS - 16462 Plastic piping and ducting systems- Determination of the long term
hydrostatic strength of thermoplastics materials in pipe form by
extrapolation
IS - 16647 Oriented Unplastized Polyvinyl Chloride (PVC-O) pipes for water

supply.
• Raw Material
• Material
The Material from which the pipe is produced shall consist substantially of
• unplasticized polyvinyl chloride to which may be added only those additives that
are needed to facilitate the manufacture of the pipe and the production of sound and
durable pipe of good surface finish, mechanical strength and opacity under
conditions of use. None of these additives shall be used separately or together in
quantities sufficient to constitute a toxic organoleptic or microbial growth hazard.
• Rework Material
The use of the manufacturer`s own reprocessed material produced during the
manufacture and works testing of products and conforming to the material
requirements of this standard is permitted. Reprocessed or recycled material obtained
from external sources shall not be used.
• VCM content
The monomer content (VCM content) in the resin shall be within the limits specified in
IS 10151
• K-value
The composition shall be based on PVC resin having a K-value of 64 or greater, when
tested in accordance with IS 4669.
• Density
When determined in accordance with IS 12235, the density of the pipe shall be between
1.40 g/cc and 1.46 g/cc.
• Material Classification
Based on the minimum required strength (MRS) values, the material shall be classified
in accordance with following Table No. 1
Table No. 1 Material Classification

Design Coefficient and Design Stress
Sr Minimum Required Pipe Material Design Design
NO Strength (MRS) Classification Coefficient, Stress,
(Mpa) Number C σ = MRS/C
(Mpa)
<1.4 32
I 45.0 450
1.6 28
<1.4 36
II 50.0 500
1.6 31
679
Manufacturing of PVC-O pipes involve process of controlled circumferential and axial

orientation of molecular structure resulting in formation of laminar structure of the material
used in the pipe construction.
• Classification of pipes:
The pipes shall be classified by their pressure ratings (Nominal pressures) (PN) at
27oC and their material class classification and design coefficient as per following
Table No. 2
Table No. 2 Pressure Rating and Working Pressure of Pipes
Sr. Design
No. Coefficient, Pressure Rating (PN)
C
I - For Material Classification- Class 450
a) 1.4 PN -- PN -- PN -- PN -- PN --
10 12.5 16 20 25
b) 1.6 -- PN 10 -- PN -- PN -- PN -- PN
12.5 16 20 25
II - For Material Classification- Class 500
a) 1.4 -- PN -- PN 16 -- PN -- PN -- --
12.5 20 25
b) 1.6 PN -- PN -- PN -- PN -- PN --
10 12.5 16 20 25
Working pressure corresponding to various pressure ratings-

Pressure Ratings Working Pressure
PN 10 1.0 Mpa (10 kg/ cm2)
PN 12.5 1.25 Mpa(1.25 kg/ cm2)
PN 16 1.6 Mpa (16 kg/ cm2)
PN 20 2.0 Mpa (20 kg/ cm2)
PN 25 2.5 Mpa (25 kg/ cm2)
680
• Valves
various locations.
• Air Valve :
velocity, the air valve can discharge the remained gas in the pipe; secondly, at the normal
working stage, the air valve can discharge the small amount of gas gathered in the pipe
timely; finally, during the pump failure or maintenance stages, the air valve will
replenish the gas into the pipe to break the vacuum. According to the orifice size,
displacement and work pressure, air valve is divided into high pressure trace exhaust
valve, low pressure air release valve and combined air valve.
• Scour Valve :
These Valves are generally provided to drain out the pipeline. The exact location of
Scour valves is frequently influenced by opportunities to dispose off the water. Where
the main pipeline crosses a stream or drainage structures, there will usually be a low
point in the line but if the main pipeline goes under the stream or drain, it cannot be
completely drained into the channel. In such a situation it is better to locate a scour
connection at the lowest point that will drain by gravity and provide for pumping out
the part below the drain pipeline.
• Control Valve :
A) Sliding Stem
• Globe valve
B) Rotary
• Butterfly valve
• Ball valve
C) Other
• Pinch valve
• Diaphragm valve

681
3 S.G.S, Mumbai
5 VJTI, Mumbai
shall be specified by the Engineer In-charge from time to time and the Contractor shall
provide free of cost all facilities towards collections of samples etc. unless otherwise
specified. Labours for collecting samples and transportation of the samples to quality
control authorities for test shall be provided free of cost by the contractor. Also
electricity, fuel, water curing tank and stores etc. shall be provided free of cost by the
contractors.
B) The materials shall be tested in QC laboratory or at any other place directed by the
be carried out as aforesaid so that he may satisfy himself regarding the procedure and
work, materials and finished item to the standard as determined by the laboratory
D) The Contractor shall make suitable arrangements to see that one of his representatives
682
Quality Assurance.

2 Laboratory Assistants(Twelveth Pass with Two to Four

(One for each L.A.)


for Sand & Metal.

• The materials, mixes and any other arrangements, including labours shall be supplied
by the contractor. The samples of testing shall be taken in the presence of Engineer-in-
Charge or his representative /QC present on site. The contractor or his authorized
683
specification.
work.

• All fittings/specials shall be fabricated or moulded at factory only. No fabrication or
moulding will be allowed at site, unless specifically permitted by the Engineer-in-
Charge.
in-Charge, the same shall be carried out at the laboratory, selected by the Engineer-
in-Charge at Contractor’s cost.

• Measurement
The specials of pipes as laid or fixed shall be measured in meter correct to a one cm as

The break up to payment for supplying, laying, jointing & hydraulic testing of pipe line shall
be as under:-
respective WUAs.
684
----------***----------
685
12.27 Hydraulic testing of PVC-O pipe line to specified pressure
(Item No. LIPDN 36)
Hydraulic testing of PVC-O pipe line to specified pressure including cost of all materials and
labour and water for testing for specified length including cutting, placing end cap making
arrangement for filling safe water using reciprocating type pumps which should be able to
provide specified test pressure gauges and other necessary equipments, labour, operation
charges, etc. required for testing. The rate under this item shall also include cost of retesting, if
necessary and reinstating to original position.(for all class of pipe)
This specification covers the requirements for hydraulic testing at works and site of PVC-O
used for water supply including cost of all materials and labour and water for testing for
specified length including cutting, placing end cap making arrangement for filling safe water
using reciprocating type pumps which should be able to provide specified test pressure gauges
and other necessary equipments, labour, operation charges, etc. required for testing. The rate
under this item shall also include cost of retesting, if necessary and reinstating to original
position.(for all class of pipe)
• Field Testing of Pipeline system.

• General
All pipelines should be tested before being brought into service. The test should be a

The test should confirm to following conditions
a) be carried out at ambient temperature;
b) be applied for at least 1 h, but not more than 24 h; and
c) not exceed 1.5 times the maximum rated pressure of the lowest rated component.
• Test Procedure
• Pipe systems should be hydraulically tested in lengths appropriate to the
diameters and site conditions. Pipelines longer than 800 m may require testing
in sections. Preferably, the length selected for test is between 300 m and 500 m.
• Testing should not take place until any concrete used for anchoring has fully
cured (normally 72 h) and attained its required strength. Solvent cemented joints
must be allowed to harden for a minimum of 24 h before being subjected to test
conditions.
686
• It is important to provide sufficient backfill over the main barrel of the pipe, to
prevent displacement and to maintain stable temperature conditions. Leave joints
free for inspection.
encourage expulsion of air as the pipe is being filled with water. Adequate air
release mechanisms should be located at all high points along the line.
• Before filling the pipeline, all line valves and air venting systems should be
checked open. All air must be removed from the system.
• Fill the system slowly. Water velocity must not exceed 0.6 m/s. Potable water
pipelines should be tested with potable water only. After charging, close all air
valves and check proper action of automatic valves.
• Allow the system to stabilize under a nominal pressure for a minimum of 2 hours.
Apply pressure steadily. Observe pressure gauges throughout and record the
rates of pressure increase.
• The pressure should be increased till the specified pressure is reached at the
lowest part of the section. Maintain test pressure at this level, by additional
pumping if necessary, for a period of 1 hour.
• Close all valves and disconnect the pressurizing unit. No further water should be
allowed to enter the system for a further period of 1 hour.
connections.
• Leak Detection
• If there has been a decrease in pressure during this period other than due to
leakage, the original pressure is re-established by injecting a measured quantity
of water into the section.
a) there is no decrease in pressure (a slight rise in pressure is also, possible due
to changes in ambient temperatures),
b) the measured quantity of water required to reinstate the pressure to the
original test pressure is less than the ‘permissible maximum’ Q,
Where,
Q = 4.5 liters per 1.6 km per 25 mm of nominal bore per 30 m head of test
• On completion of any test, the residual pressure should be released slowly and
in a carefully controlled manner.
• All defects revealed in the test should be rectified and the procedure repeated
until a satisfactory result is obtained.
• If any leakage is found during testing of pipeline, Contractor will have to attend
the same immediately and rectify at his cost . If Contractor fails to rectify the
defect, the entire length of pipeline between two adjacent outlets shall be
rejected. If any intermediate payment is made to the Contractor for portion under
rejection, the same shall be recovered from the outstanding dues of the
Contractor.
687
Third party Inspection can be done form any one of the following services or
3 S.G.S, Mumbai
5 VJTI, Mumbai
B) The materials shall be tested in QC laboratory or at any other place directed by
688
D) The Contractor shall make suitable arrangements to see that one of his
Quality Assurance.


(One for each L.A.)
contractor.

for Sand & Metal.

689
specification.
work.

• The test should confirm to following conditions
a) be carried out at ambient temperature;
b) be applied for at least 1 h, but not more than 24 h; and
c) not exceed 1.5 times the maximum rated pressure of the lowest rated component.
• Pipe systems should be hydraulically tested in lengths appropriate to the diameters and
site conditions. Pipelines longer than 800 m may require testing in sections. Preferably,
the length selected for test is between 300 m and 500 m.
• Testing should not take place until any concrete used for anchoring has fully cured
(normally 72 h) and attained its required strength. Solvent cemented joints must be
allowed to harden for a minimum of 24 h before being subjected to test conditions.
• It is important to provide sufficient backfill over the main barrel of the pipe, to prevent
displacement and to maintain stable temperature conditions. Leave joints free for
inspection.
encourage expulsion of air as the pipe is being filled with water. Adequate air release
mechanisms should be located at all high points along the line.
690
• Before filling the pipeline, all line valves and air venting systems should be checked
open. All air must be removed from the system.
• Fill the system slowly. Water velocity must not exceed 0.6 m/s. Potable water pipelines
should be tested with potable water only. After charging, close all air valves and check
proper action of automatic valves.
• Allow the system to stabilize under a nominal pressure for a minimum of 2 hours. Apply
pressure steadily. Observe pressure gauges throughout and record the rates of pressure
increase.
• The pressure should be increased till the specified pressure is reached at the lowest part
of the section. Maintain test pressure at this level, by additional pumping if necessary,
for a period of 1 hour.
• Close all valves and disconnect the pressurizing unit. No further water should be allowed
to enter the system for a further period of 1 hour.
connections.
• If there has been a decrease in pressure during this period other than due to leakage, the
original pressure is re-established by injecting a measured quantity of water into the
section.
c) there is no decrease in pressure (a slight rise in pressure is also, possible due to changes
in ambient temperatures),
d) the measured quantity of water required to reinstate the pressure to the original test
pressure is less than the ‘permissible maximum’ Q,
Where,
Q = 4.5 liters per 1.6 km per 25 mm of nominal bore per 30 m head of test pressure per 24
hours.
• On completion of any test, the residual pressure should be released slowly and in a
carefully controlled manner.
• All defects revealed in the test should be rectified and the procedure repeated until a
• If any leakage is found during testing of pipeline, Contractor will have to attend the
same immediately and rectify at his cost. If Contractor fails to rectify the defect, the
entire length of pipeline between two adjacent outlets shall be rejected. If any

• Measurement
The Hydraulic testing of pipes as laid or fixed shall be measured in Kilometer correct
to one metre. Specials shall be excluded and measured in Kilogram or numbers as
691
• Payment
shall be as under:-
of respective WUAs.


----------***----------
Note
• Operation, Maintenance and Handing over of the System
detect or confirm any leakage in the system and rectify at his own cost. The testing shall
preferably be conducted jointly with members of WUA/representative of Engineer In-
charge, technical representative of contractor and any other stake holder.
• During the O & M period, contractor shall give training to the members of WUA about
O & M of PDN work and its efficient use and protection of the system from any
damages.
record to WUA. Along with this, the detailed Geotagged map of laid pipeline shall also
be handed over to WUA.
692
• In association of the members of WUA, the Engineer In-charge shall confirm the release
of designed discharge through every outlet before handing over. In case of any short
fall or defect, it should be made good from the contractor at his own cost.
----------***----------
693
SPECIFICATION FOR PRESTRESSED CONCRETE NON CYLINDER PIPES (P.S.C.)
12.28 Providing and supplying ISI standard Pre-stressed Cement concrete pipes
(Item No. LIPDN 37)
Providing and supplying ISI standard Pre-stressed Cement concrete pipes of following class
and diameter including cost of all material and labour required, cost, inspection charges,
transportation to stores, unloading and stacking excluding GST levied by GI & GOM in all
respect etc. complete as per IS-784-2001.

This Specification covers the requirements for providing and supplying at works and site of
Pre-stressed Concrete Non-Cylinder Pipe (PSC) pipes used for water supply.
Introduction
Pre-stressed Concrete Non-Cylinder Pipe is suitably compacted concrete core longitudinally
pre-stressed with pre-tensioned high tensile steel wire embedded in the concrete,
circumferentially pre-stressed and coated with cement mortar or concrete to protect the
circumferential pre-stressing wire, to withstand internal pressure and external design loads.
The Contractor shall provide on-site training on PSC pipe laying, jointing, testing and
maintenance etc., to the personnel authorized by Engineer-in-Charge. The contractor should
provide technical Manual on PSC pipes including precautions to be taken during operation of
the pipeline.
 Applicable IS Codes
The manufacturing, testing, supplying, laying, jointing and testing at work sites of PSC pipes
shall comply with all currently applicable statutes, regulations, standards and Codes. In
particular, the following standards, unless otherwise specified herein, shall be referred. In all
694
cases the latest revision of the Codes shall be referred to. If requirements of this Specification
conflict with the requirements of the standards/Codes, this Specification shall govern. Others
Codes not specifically mentioned here but pertaining to the use of PSC Pipes form part of
these Specifications.
IS: 784 Specifications for Prestressed Concrete pipes (Including specials)
IS:783 Code of practice for Laying of Concrete Pipes
IS:3597 Methods of Test for Concrete pipes
IS 1785 Specifications for Plain Hard –drawn steel wire for Prestressed
Part 1, Part 2 Concrete.
IS 383 Specifications for coarse and fine aggregates from natural sources for
concrete
IS 1566 Specifications for Hard Drawn Steel Wire for Concrete Reinforcement
IS:2062 Specification for steel for General Structural purposes
IS: 5382 Specification of Rubber Sealing Rings for Gas Mains, Water Mains &
Sewers
 Raw Materials
Raw materials used to manufacture PSC Pipes are cement, aggregates, water, admixture, steel
reinforcement, steel for specials, rubber sealing rings.
 Cement
The cement used in the manufacture of PSC pipes shall conform to one of the
following.
1. 43/53 grade Ordinary Portland Cement conforming to IS:8112/IS 12269

2. Rapid Hardening Portland cement conforming to IS: 8041
3. Portland Slag cement (with not more than 50% slag) conforming to IS: 455
4. Sulphate resisting Portland Cement conforming to IS: 12330
 Aggregate
The coarse and fine aggregates shall conform to I.S.383. The maximum size of
aggregate shall not exceed one third the thickness of the pipe or 20mm whichever is
smaller. Silt Content in fine aggregates shall be less than 3 percent. The fineness
modulus of aggregates for coating shall be between 2.6 to 3.2.
 Water
695
 Admixtures
conform to IS 9103.
 Steel wires
Prestressing steel wire shall conform to IS 1785.
 Steel for Specials

Steel plates for Specials shall conform to IS: 2062
 Rubber Sealing Rings

• Rubber sealing ring shall comply with IS 5382
• Every ring shall be visually checked for defects, particularly at joints.
• Sealing ring shall be clearly labelled in bundle to indicate type of joints, internal
diameter and name of manufacturer.
• Not more than 2 splices in each ring shall be permitted.
• Composition of natural rubber in sealing ring shall be as per IS 784.
 Manufacturing of Pipes and Specials

The Manufacturing of pipes and specials for PSC pipes shall be as per IS 784. The mould and
method of manufacture of pipe shall be such that the form and dimensions of the finished pipe
conform to IS 784 and the surface and edges of the pipes are clean and true. Various steps
involved in pipe manufacturing process are as given below.
 Longitudinal pre-stressing of high tensile wires.

 Placing of concrete in the core either by the centrifugal method or vertical casting
method (Minimum cement content -350 kg/m3, Maximum W/C ratio - 0.5 and
Minimum compressive strength at 28 days - 40 N/mm2) with a smooth inner surface.
 Spiral winding of high tensile wires on cured concrete core.
 Rich cement mortar out coating (cover coating) on pipe.(minimum cement content-
540kg/m3, minimum water cement ratio– 0.27, minimum compressive strength of
cement mortar at 28 days-35 N/mm 2).
 Curing of pipe.
696
Cross-section of PSC Pipe Joint
PSC pipe shall be designed to withstand the combined effects of internal water pressure &
external loads. Design of PSC pipes shall be site specific as internal water pressure will
depend on pipe profile whereas external loads will depend on maximum cover (i.e.
overburden) over the crown of pipe.
 Sampling criteria for Selection of Pipe for Testing Purpose

All the pipes manufactured under relatively similar conditions in respect of raw-materials and
processing operation, shall be grouped together to constitute a lot Each lot shall be taken
separately for sampling and evaluation, for conformity to the requirements of IS 784. Scale of
sampling shall be as given in following Table No.1.
Table No.1 Scale of Sampling and No. of Acceptable defective tests (Reproduced from IS
784)
697
 Pre Delivery Testing of Pipes
Pipe selected as per sampling criteria mentioned in above para 5.0 are subject to following
1) Dimensions - Length, Internal diameter, Core thickness, straightness and finish.

2) Hydrostatic Factory Test
3) Permeability Test on Coating
4) Mortor soundness test
 Dimensions
1. Length -
Length of Pipe shall be 2 to 6m. For pipes up to and including 300mm
diameter, the length shall not be more than 3m.
2. Nominal internal diameter of the pipe and minimum core thickness shall be as
per following Table No. 2
Table 2 Nominal Internal Diameter and Minimum Core Thickness of Pipes
Nominal Internal Minimum Core Nominal Internal Minimum Core

Diameter of Pipe Thickness Diameter of Pipe Thickness
(mm )
(mm ) (mm ) (mm )
200 35 1300 75
250 35 1400 75
300 35 1500 80
350 35 1600 85
400 35 1700 90
450 35 1800 95
500 35 1900 100
600 40 2000 105
700 40 2100 110
800 45 2200 115
900 55 2300 120
1000 60 2400 125
1100 65 2500 130
1200 70 - -
Note : Core thickness for pipes needs to be designed based on internal hydrostatic
pressure and external overburden, based on actual site conditions.
698
3. The deviation from straight line taken between two points one meter apart,
along the pipe barrel shall not exceed 5mm.
4. The pipe shall be free from local depressions or bulges greater than 5mm
extending over a length, in any direction.
 Hydrostatic Factory Test

The pipe shall be subjected to hydrostatic test after coating in accordance with IS
3597. For this test, the pipe is placed on a hydrostatic test bench, filled with water and
pressure has to be raised slowly up to designed factory test pressure. Pressure shall be
maintained by pumping water as per IS 3597.
The pipe must not show leakage. Damp or wet patches shall be accepted. If the pipe
fails to pass the test, it can be cured or repaired to improve its water tightness and then
retested. In case the pipe does not stand the rated internal pressure, it shall be accepted
for lower pressure to which it withstands, at the discretion of Engineer-in-charge,
provided all other requirements are conforming to this standard.
 Permeability Test on Coating

The drop of water level, in the specimens of pipes selected when tested according to
method described in IS 3597 shall not exceed 2 cm3 at the end of two hours and the
final permeability between fourth and fifth hours shall not exceed 0.3 cm3. When a
higher result is obtained, the test shall be repeated on twice the number of pipes
originally tested and the lot shall be accepted, if all pipes pass the test. Where retest is
not satisfactory, all pipes from that lot may be tested individually and only those with
satisfactory results shall be accepted. No additional treatment of any type shall be
allowed on the pipe before permeability test is taken. The test shall be done
immediately after the hydraulic factory test. In case this is done later, then the pipe has
to be kept wet for 48 hrs prior to test.
 Mortor soundness test

After the mortar coating is cured and prior to transport, the coating on each pipe shall
be checked for delamination and hollows by tapping the exterior with hammer having
head of mass of not more than 0.5 kg. Any hollows or drumming areas detected by
sounding shall be repaired by approved method.
 Marking on Pipes

2. Pressure rating.
3. Nominal diameter
699
7. Name of Department/Project for which pipes are manufactured.
8. Any other important matter that the manufacturer or purchaser deems fit to be inscribed.
 Transportation of Pipes
 The vehicle shall have side supports approximately spaced 2m apart, and the pipes shall be
secured effectively during the transportation. All posts shall be flat with no sharp edges.
 A pipe section must be rolled or otherwise moved, such operation shall be done slowly and
with every reasonable precaution against damage. Any portion of the lining, coating that
may become damaged shall be repaired with polymer Mortar.
Pipes manufactured at factory are to be carried to the site of work directly or stacked suitably
and neatly along the alignment/ road side/elsewhere near by the work site, as directed by
the Engineer.
All pipes shall be loaded in trucks by mechanical crane/ tripod and unloaded carefully using
crane/ tripod. No unloading using crow bars or on tires will be allowed in any case. Rubber
belt may be used instead of crow bars or chains.
Pipes should be loaded at the works for transportation, either by rail or by road, in such a way
that they are secure and that no movement can take place on the vehicle during transit. The
same care is needed if pipes are to be transferred from one vehicle to another, however,
short the journey may be.
Un-loading of pipes should be carried out by means of chain block with shear legs or crane of
adequate capacity, using properly designed slings and spreader beams or specially designed
lifting beams. Slings should be placed around the circumference of the pipe and should not
be threaded through the pipe bore' as the latter method may damage the jointing surfaces.
For the same reasons, hooks located in the ends of the pipes should not be used.
Typical Lifting beam
 Stacking Of Pipes at Site

damages to pipes.
 Pipes may be placed directly on the ground provided it is reasonably level and free from
rocks and other projections.
700
 Stacking in tiers is permissible provided timber bearers are placed between succeeding
tiers.
 Rolling down of the stacked pipes must be avoided by providing wedges wherever
required.
 All pipes shall be loaded /unloaded on/from truck by mechanical crane only. No hook
shall be used and nylon tape of sufficient size and width shall be used.
 Valves
various location.
 Air Valve :
areas: firstly, in the waterfilled stage of the pipeline, filled with water by a certain
normal working stage, the air valve can discharge the small amount of gas gathered in
the pipe timely; finally, during the pump failure or maintenance stages, the air valve
will replenish the gas into the pipe to break the vacuum. According to the orifice size,
 Scour Valve :
 Control Valve :
A) Sliding Stem
 Globe valve
 Angle body valve
 Angle seat piston valve
B) Rotary
 Butterfly valve
 Ball valve
C) Other
 Pinch valve
 Diaphragm valve
701
 Post-delivery testing of pipes
After delivery of pipes to worksite, additional test, if desired by Engineer-in-charge, shall be
given in for going Para for pre delivery testing of pipe.
 Third Party Inspection

 Work of PDN shall be inspected, tested and certified by PMC / TPI / QC. Modalities of PMC
3 S.G.S, Mumbai
5 VJTI, Mumbai
6 CWPRS (Central Water & Power Research Station), Pune
 Testing of materials
mortar etc. shall be specified by the Engineer In-charge from time to time and the
by the contractor. Also electricity, fuel, water curing tank and stores etc. shall be
whether all materials, workmanship are of respective standard described in
contract and in accordance with the instructions of the Engineer In-charge. The
Contractor’s representatives shall, however, be given access to all operations and
the procedure and methods adopted. It shall then be the Contractor’s responsibility
to produce on the work, materials and finished item to the standard as determined
by the laboratory tests or to take follow up action to rectify the quality.
702
authenticate the facts. If the Contractor, fails to keep his representative present at
site at the time of taking samples or fail to provide required labours and other
 Quality Control and Quality assurance
1. On award of contract, the Contractor will have to provide adequate quality
charge.
2. Following minimum persons shall be employed by the contractor at work site for
Quality Assurance.
1 Quality Assurance Engineer (Civil Engineering One

2 Laboratory Assistants (Twelfth Pass with Science Two to Four

material) (As per work)
(One for each

L.A.)
 Following minimum equipments shall be available in the field laboratory setup by the
contractor.

for Sand & Metal.

Slump, Cube Moulds &CTM
 It is the responsibility of the contractor to assure the desired quality of work. Whenever the
selected by the Engineer-in-Charge at Contractor’s cost. The other test for mortar, concrete,
703
presence of quality control representative at contractor’s cost. Contractor shall through this
 The materials, mixes and any other arrangement s, including labours, shall be supplied by the
contractor. The samples for testing shall be taken in the presence of Engineer-in-Charge or
his representative /QC present on site. The contractor or his authorized representative shall
have a free access in these laboratories, to get himself satisfied about procedures of testing
etc. Even if the contractor or his representative fails to remain present while collecting
samples or testing, the results will be considered as authentic and binding on the contractor.
 Contractor shall provide all test reports of material used in the work as desired from the
NABL (National Accreditation Board for Testing & Calibration Laboratories) approved
laboratories and from Quality Control, MERI laboratories of the WRD. Contractor shall
provide periodical quality assurance report (Weekly/fortnightly/monthly) to Engineer in
Charge along with proofs in support of quality of material brought for the work, the process/
execution of work is as per specification.
 Contractor shall submit the account of all materials brought for the work, which are
necessary for execution of work and any other data necessary to assess the quality of work.
 If he fails to fulfill the above requirement, the required manpower for testing and field
 Sequence of Execution
 The Manufacturing of pipes and specials for PSC pipes shall be as per IS 784.
 Pre Delivery Testing of Pipes shall be done for conformity to the requirements of IS 784 in
the presence of representative of Engineer-In-charge /WRD/QC/TPI.
 Pipes are subject to following tests before delivery from factory.
1. Dimensions - Length, Internal diameter, Core thickness, straightness and finish.
2. Hydrostatic Factory Test
3. Permeability Test on Coating
4. Mortor soundness test.
 Each pipe shall be indelibly marked in English language at either end of each pipe. Like
Manufactures name or trademark, Grade of raw material , Pressure rating, Nominal diameter,
Lot/batch No. of manufacturer, BIS certification mark, Third Party Certification mark for
each lot , Name of Department/Project for which pipes are manufactured. Any other
important matter that the manufacturer or purchaser deems fit to be inscribed etc.
 Supply of pipes - The vehicle shall have side supports approximately spaced 2m apart, and
the pipes shall be secured effectively during the transportation. All posts shall be flat with no
sharp edges.
 Any portion of the lining, coating that may become damaged shall be repaired with polymer
Mortar.
 Pipes manufactured at factory are to be carried to the site of work directly or stacked suitably
and neatly along the alignment/ road side/elsewhere near by the work site, as directed by the
Engineer.
 All pipes shall be loaded in trucks by mechanical crane/ tripod and unloaded carefully using
crane/ tripod. No unloading using crow bars or on tires will be allowed in any case. Rubber
belt may be used instead of crow bars or chains.
 Pipes should be loaded at the works for transportation, either by rail or by road, in such a way
that they are secure and that no movement can take place on the vehicle during transit. The
same care is needed if pipes are to be transferred from one vehicle to another, however, short
the journey may be.
704
 Un-loading of pipes should be carried out by means of chain block with shear legs or crane
of adequate capacity, using properly designed slings and spreader beams or specially
designed lifting beams.
 Pipes manufactured at factory are to be carried to the site of work directly or stacked suitably
and neatly along the alignment/road side/elsewhere near by the work site or as directed by the
Engineer-in-Charge.
 Stacking of pipes should be done with precautions to eliminate potential damages to pipes.
 All materials before being utilized in works shall be inspected and tested, by the Engineer In-
charge or his representative/QC.
 After delivery of pipes to worksite, additional test, if desired by Engineer-in-charge, shall be
conducted on random samples of pipes collected from site.
 The desired quality of work. Whenever the testing of construction materials, pipes are
 The net length of pipes as laid or fixed shall be measured in running meters correct to a cm.
 Damages during transit, handling, storage will be to the Contractor’s account and replacement
for such pipes has to be made by the Contractor without any extra cost as directed by the
Engineer-in-Charge.

shall be as under:-
A. 80% of the payment will be released after supplying, lowering, laying, jointing
of respective WUAs.
1. After Successful Operation and Maintenance for First year-2%

2. After Successful Operation and Maintenance for Second year-2%
3. After Successful Operation and Maintenance for Third year-2%
4. After Successful Operation and Maintenance for Fourth year-2%
5. After Successful Operation and Maintenance for Fifth year-2%
----------***----------
705
12.29 Lowering, laying and jointing in proper grade and alignment Pre-Stressed
Cement Concrete Pipes (Item No. LIPDN 38)
Lowering, laying and jointing in proper grade and alignment Pre-Stressed Cement
Concrete Pipes with rubber ring joints including cost of conveyance from stores to
site of works, all labour involved, etc. complete but excluding cost of rubber rings
(For all class of pipes).

This Specification covers the requirements for lowering, laying and jointing at works and
site of Pre-stressed Concrete Non-Cylinder Pipe (PSC) pipes used for water supply mains.

 Clearing the Site
The Contractor shall clear the entire area required for setting out. All tree stumps,
materials shall be removed by the Contractor. Buried irrigation pipeline, and other
structure, if any, shall be removed by the Contractor. The ownership of all the usable
material, so removed from clearing site and/or excavation shall rest with the Engineer
In-charge. Useful material shall be stacked as directed. The Contractor shall dispose
off all un-useful materials as directed by the Engineer In-charge.
 Demarcation
All materials such as pegs, bamboo’s and strings and templets for marking out slopes,
The center line of excavation shall be clearly marked by pegs or by stones at each
 Contractor shall provide and maintain the quarry roads and temporary roads required
 Fixing Permanent Benchmark

(a) Benchmarks fixed by the Survey of India and temporary benchmarks established by
benchmark.
706
Contractor.
2. Theodolites (Accuracy1second) 1No.
3. Levels 2Nos.
4. Staves 4Nos.
made available in advance of starting of the work. All equipment
Shall be maintained, repaired and got tested and certified as and when required for it
accuracy from the standard test houses or from the manufactures and to the
 Excavation for Pipe Trenches

 Excavation of pipe trenches shall be carried out as per excavation line shown in the drawing
or as directed by Engineer In -charge. Contractor must assume all responsibility for
deductions and conclusion made by him as to the nature of the materials to be excavated and
the difficulties of making and maintaining the required excavation. The trench width at
bottom shall be 300 mm more than 1.5 times outside pipe diameter. In any case trench width
shall not be less than 500 mm.
 The usable excavated material available from the excavated trenches (PDN) shall be used in
shall be deposited in the spoils as and where directed by the Engineer In-charge. Un-useful
material from excavation shall be deposited in spoils as and where directed by Engineer-In-
charge.
 Surface or sub-soil water met with during trench excavation (PDN) and structure excavation
shall be diverted to nearby drain/nalla by cutting an open channel from trench. When the
707
drain/nalla bed is higher than the sub-soil water level met with, the bailing out by suitable
means of pumping shall be resorted to for dewatering sub-soil water below the drain/nalla bed
level. No distinction shall be made as to whether the material being excavated is dry, moist,
wet or slushy. The Contractor shall have to excavate the PDN pipe trench and structure in
under water level conditions also i.e. under wet/slushy condition after providing sufficient
arrangement of dewatering. The material excavated under water level condition which
requires intermediate stacking for drying shall have to be re-handled. No extra payment for
efforts for drying out of soil, re-handling of dry soil, etc. shall be given. No payment for extra
efforts for excavation under this condition shall be made.
 Over excavation performed by the Contractor for any purpose or reason, except for additional
excavation as may be directed by the Engineer-In-charge, shall be rectified at the cost of the
Contractor. Filling and compaction for such over excavation using the material as directed by
the Engineer In-Charge shall also be at the cost of the Contractor.
 In the PDN and structure section where expansive type of the soil such as CH type of soil is
be over excavated to the extent as directed by the Engineer In Charge and such over
excavated section shall be filled with suitable murum type soil to be placed in uniformly
compacted layers as directed by the Engineer In Charge. The over excavation made in such
strata, filling by suitable soil, and watering and compacting such soil will be paid separately
under relevant items. Above provision for over excavating and filling with suitable murum
type or good soil available material shall be applicable in case such treatment is found
essential.
 Laying of Pipes
While laying of PSC pipe, all precaution as mentioned in IS 783 shall be taken. Concrete
pipes have to be properly handled, bedded & back filled, if they have to carry the full design
loads safely.
 Pipes should be lowered into the trench with tackle suitable for the weight of pipes,
 While lifting, the position of the sling should be checked when the pipe is just clear off
the ground to ensure proper balance.
 Laying of pipes shall preferably proceed upgrade of a slope.
 When laying is not in progress, the open end of the pipe line should be fitted with
• When gradient for pipe laying is steeper than 1 in 6, suitable transverse anchor blocks
as specified in IS 783 shall be provided for anchoring of pipeline.
• Expansion joints shall be provided for buried lines at maximum interval of 100m, if
rigid joints are used.
Each pipe shall be thoroughly checked for any damages before laying and only the
• Bedding requirements for this pipe are minimal due to rigid nature of pipe. However,
while laying in rocky area, 150 mm compacted fine sand bedding under and around
 Jointing of Pipes
 Jointing of pipes shall be done as per procedure mentioned in IS 783.The sections of the pipe
should be jointed together in such a manner that there shall be as little unevenness as possible
708
along the inside of the pipe. As soon as joint assembly is complete, the last pipe laid should
be firmly restrained in position until backfilling over it is complete and well compacted.
 The joint are mainly of two types, viz. rigid joints and Flexible joints.
Rigid joints - In this type of joint, the water seal is affected by cement mortar or similar
material which will not allow any movement between the two pipes. These joints can be of
three types as mentioned below.
 Socket and Spigot Joint- The annular space between socket and spigot is filled with cement
mortar (1:2). This joint is used for low pressure pipe line.
Socket and Spigot Joint
 Collar Joint- Collars of 15to 20 cm wide cover the joint between two pipes. A slightly damp
mixtures of cement and sand is rammed with caulking tool.
Collar Joint ( Rigid )
 Flush Joint: This joint can be internal or external as given below.
(a) Internal flush joint- This joint is generally used for culvert pipes of 900 mm diameter and
over. The ends of the pipes are specially shaped to form a self-centering joint with an
internal jointing space 1.3 cm wide. The finished joint is flush with both inside and outside
with the pipe wall. The jointing space is filled with cement mortar mixed sufficiently dry to
remain in position when forced with a trowel or rammer.
709
Internal flush joint (Rigid)
(b) External flush joint- This joint is suitable for pipes which are too small for jointing from
inside. Great care shall be taken in handling to .ensure that the projecting ends are not
damaged as no repairs can be readily effected from inside -the pipe.
External flush joint (Rigid)
• Flexible Joints - In this type of joint, the water seal is affected because of contact pressure
between the sealing rubber ring (or similar material) and the pipe surface.
These are mainly of two types.
1. Roll on Joint- A rubber ring (circular in cross-section) is placed at or near the
end of the spigot and rolls along it as the spigot enters the socket.
710
Roll on Joint (Flexible)
2. Confined Gasket- Rubber ring of circular cross -section is held in the groove formed
on the spigot. Sometimes, the cross-section is in the shape of lip. The lips are opened
due to water pressure which ensure water seal. For assembly of this joint, a lubricant
has to be applied to the sliding surfaces. The lubricant washes off when the pipe is in
service.
Confined O-Ring Joint (Flexible)
 The basic requirements for all types of joints mentioned above are as enumerated below.
a) cleanliness of all parts, particularly joint surface;

b) correct location of components;
c) centralization of spigot within socket;
d) Provision of the correct gap between the end of the spigot and the back of the
socket (for rubber ring joint) to ensure flexibility at each joint; and any
lubricant used shall be approved as to composition and method of application.

 The type of material used for backfilling and the manner of depositing the material,
shall be subject to approval by the Engineer-in-Charge.
 The backfill material shall be placed to the line and grades as shown on drawings or as
 The backfill material shall be placed carefully and spread in uniform layers of not more
than 15cm thickness, with the first layer watered and compacted by stamping or by
711
mechanical means. The backfill shall be brought up as uniformly as practicable on both
sides of pipe to prevent unequal loading.
 Only soft earth and gravel of good quality free from boulder, roots, vegetable matters
 When compacting the soil against steep rock, abutment walls of concrete structures,
structure. The backfill close to the structure up to the rolled layer shall be compacted in
suitable uniform layers, using pneumatic / hand tampers as appropriate for dry density
at average bulk density (+/- 10%). The moisture content of the earth fill placed against
the rock or the structure shall be on higher/lower side of OMC by about 2% or so, to
allow it to be compacted. Profuse watering shall be done to pervious materials (sand)
before compaction as per instruction of the Engineer-in-Charge. Compaction at junction
of earthwork and backfill around the structure shall be carried out with special care.
 The trench shall be refilled so as to built-up the original ground level.
farmers.
(15x15x45)CM embedded in concrete block of size (30x30x30)CM. The base of this
block shall be buried in ground projecting only 15cm above the ground and the base
concrete block.
• These blocks shall be able to locate the pipeline as and where it is laid all over the work.
The contractor shall mark each block with specific distinct identification mark.
period of the contract. Any damage done to these blocks for the reasons whatsoever shall
be made good at the cost of contractor.
• The contractor shall submit the location of such blocks with specific identification marks
with schedule on a special command area map.
• The map of marking of the block shall be handed over to WUA while handing over the
command area.

Work of PDN shall be inspected, tested and certified by PMC / TPI / QC. Modalities of PMC /
TPI / QC Inspection shall be separately decided and given by Engineer In-charge.
712
Project management consultants (PMC) should have approved laboratories certification or
Laboratories)
Third party Inspection can be done form any one of the following services or from any
3 S.G.S, Mumbai
5 VJTI, Mumbai
713
On award of contract, the Contractor will have to provide adequate quality
laboratory assistants, labours and well-equipped laboratory for taking necessary
charge.
 Following minimum persons shall be employed by the contractor at work site for Quality
Assurance.

2 Laboratory Assistants (Twelfth Pass with Science Two to Four

(One for each

L.A.)
 Following minimum equipments shall be available in the field laboratory setup by the
contractor.

for Sand & Metal.

714
 The materials, mixes and any other arrangement s, including labours, shall be supplied by the
his representative /QC present onsite. The contractor or his authorized representative shall

 The Contractor shall clear the entire area required for setting out. All tree stumps,
 All materials such as pegs, bamboo’s and strings and templets for marking out slopes,
 The center line of excavation shall be clearly marked by pegs or by stones at each
final lineout will be done by fixing references to neat suitable distances on either side
construction period.
 Prior permission of other department like P.W.D., H.P.C.L, M.J.P. shall be taken if
the alignment of pipe line crosses railway line, roads, gas pipe lines etc.
 Benchmarks fixed by the Survey of India and temporary benchmarks established by
 Before starting any work, the Contractor shall erect reference benchmarks, reference
 All materials, labour and equipments (theodolites, levels, distometre, etc.) for setting
 Excavation of pipe trenches shall be carried out as per excavation line shown in the
 The usable excavated material available from the excavated trenches (PDN) shall be
Engineer In-charge.
 In the PDN and structure section where expansive type of the soil such as CH type of
715
placed in uniformly compacted layers as directed by the Engineer In-Charge. The
over excavation made in such strata, filling by suitable soil, and watering and
compacting such soil will be paid separately under relevant items. Above provision
for over excavating and filling with suitable murum type or good soil available
material shall be applicable in case such treatment is found essential.
 While laying of PSC Pipes, all precautions as mentioned in IS 783 shall be taken.
 Valve like Air valve, Scour Valve and Control valve shall be constructed as per
drawings.
 While lifting, the position of the sling should be checked when the pipe is just clear
 When gradient for pipe laying is steeper than 1 in 6, suitable transverse anchor blocks
 Expansion joints shall be provided for buried lines at maximum interval of 100m, if
 Each pipe shall be thoroughly checked for any damages before laying and only the
 Bedding requirements for this pipe are minimal due to rigid nature of pipe. However,
while laying in rocky area, 150 mm compacted fine sand bedding under and around
 The trench shall be kept free of water till the jointing has been properly done.
 Jointing of pipes shall be done as per procedure mentioned in IS 783.
 The sections of the pipe should be jointed together in such a manner that there shall
be as little unevenness as possible along the inside of the pipe. As soon as joint
assembly is complete, the last pipe laid should be firmly restrained in position until
backfilling over it is complete and well compacted.
 The backfill material shall be placed to the line and grades as shown on drawings or
as prescribed in this paragraph or as directed by the Engineer-in-Charge.
 Permanent markings of Pipe alignment
 The contractor shall establish the sufficient number of reference blocks on the
farmers.
 Third party inspection - Work of PDN shall be inspected, tested and certified by PMC
/ TPI / QC. Modalities of PMC / TPI / QC Inspection shall be separately decided and
given by Engineer In-charge of the work.
 All materials before being utilized in works shall be inspected and tested, by the
716
relevant IS Codes and determined by the Engineer In-charge.
 The contractor must assure the desired quality of work. Whenever the testing of
construction materials, pipes are required as per the detailed specifications or
otherwise required by the Engineer-in-Charge, the same shall be carried out at the
laboratory, selected by the Engineer-in-Charge at Contractor’s cost.

• Measurement
The Lowering, Laying & Jointing of pipes as laid or fixed shall be measured in
running meters correct to a cm. Specials shall be excluded and measured in running
meters or numbers as specified by Engineer-in-charge and paid for separately under
the relevant item. The portion of the pipe overlapped at the joints shall not be included
in the length of pipe work. Excavation, refilling, anchor blocks, thrust blocks wherever

• Payment
of respective WUAs.

----------***----------
717
12.30 Providing and supplying ISI standard specials & fitting suitable for P. S. C.
Pipes (Item No. LIPDN 39)
Providing and supplying ISI standard specials & fitting suitable for P. S. C. pipes including
cost of labour, materials, and transportation to stores / site, loading and
Un-loading excluding GST levied by GOI & GOM in all respect, complete.
This specification covers the requirements of pre-stressed concrete pipes specials and fitting
with nominal internal diameter 10 the range of 200 mm to 2 500 mm including cost of labour,
materials, and transportation to stores / site, loading and unloading excluding GST levied by
GOI & GOM in all respect, complete.
• Introduction
Prestressed Concrete Non-Cylinder Pipe is suitably compacted concrete core longitudinally
prestressed with pretensioned high tensile steel wire embedded in the concrete,
circumferentially prestressed and coated with cement mortar or concrete to protect the
circumferential prestressing wire, to withstand internal pressure and external design loads.
The Contractor shall provide on-site training on PSC pipe laying, jointing, testing and
provide technical Manual on PSC pipes including precautions to be taken during operation of
the pipeline.
The manufacturing, testing, supplying, laying, jointing and testing at work sites of PSC pipes
Codes not specifically mentioned here but pertaining to the use of PSC Pipes form part of
718
Part 1, Part 2 Concrete.
concrete
IS: 5382 Specification of Rubber Sealing Rings for Gas Mains, Water Mains &
Sewers
• Raw Materials
Raw materials used to manufacture PSC Pipes are cement, aggregates, water, admixture, steel
reinforcement, steel for specials, rubber sealing rings.
• Cement
The cement used in the manufacture of PSC pipes shall conform to one of the
following.

8. Sulphate resisting Portland Cement conforming to IS: 12330
9. Aggregate
• Water
719
• Admixtures
conform to IS 9103.
• Steel wires
Prestressing steel wire shall conform to IS 1785.
• Steel for Specials

Steel plates for Specials shall conform to IS: 2062
• Rubber Sealing Rings

• Rubber sealing bring shall comply with IS 5382
• Every ring shall be visually checked for defects, particularly at joints.
• Sealing ring shall be clearly labelled in bundle to indicate type of joints, internal
diameter and name of manufacturer.
• Not more than 2 splices in each ring shall be permitted.
• Composition of natural rubber in sealing ring shall be as per IS 784.

The Manufacturing of pipes and specials for PSC pipes shall be as per IS 784. The
mould and method of manufacture of pipe shall be such that the form and dimensions
of the finished pipe conform to IS 784 and the surface and edges of the pipes are clean
and true. Various steps involved in pipe manufacturing process are as given below.
 Longitudinal prestressing of high tensile wires.

method (Minimum cement content -350 kg/m3, Maximum W/C ratio - 0.5 and
Minimum compressive strength at 28 days - 40 N/mm2) with a smooth inner surface.
 Rich cement mortar out coating (cover coating) on pipe.(minimum cement content-
540kg/m3, minimum water cement ratio– 0.27, minimum compressive strength of
cement mortar at 28 days-35 N/mm 2).
 Curing of pipe.
720
Cross-section of PSC Pipe Joint
PSC pipe shall be designed to withstand the combined effects of internal water pressure &
external loads. Design of PSC pipes shall be site specific as internal water pressure will
• Valves
various location.
• Air Valve :
• Scour Valve:
721
• Control Valve:
a) Sliding Stem
 Globe valve
b) Rotary
 Butterfly valve
 Ball valve
c) Other
 Pinch valve
 Diaphragm valve
Work of PDN shall be inspected, tested and certified by PMC / TPI / QC. Modalities of PMC
Laboratories)
3 S.G.S, Mumbai
5 VJTI, Mumbai
722
Quality Control and Quality assurance
On award of contract, the Contractor will have to provide adequate quality
charge.
Following minimum persons shall be employed by the contractor at work site for
Quality Assurance.

2 Laboratory Assistants(Twelfth Pass with Science Two to Four

(One for each

L.A.)
723
Following minimum equipment shall be available in the field laboratory setup by the
contractor.

for Sand & Metal.

sand, coarse aggregates etc. shall be carried out in field laboratory set up by the contractor in
 The materials, mixes and any other arrangements, including labours, shall be supplied by the
his representative /QC present on site. The contractor or his authorized representative shall
If he fails to fulfill the above requirement, the required manpower for testing and field

 The steel for fabricated steel plate specials, is cut, shaped and welded so that finished special
has the required shape and internal dimensions. Adjacent segments are jointed by butt
welding. Before lining and coating the welding of special shall be tested by use of hot oil or
dye penetrate according to IS 3658and defects, If any shall be rectified. The steel plate
thickness for specials shall be as given in IS 7322.
 In die penetration test, a white wash is applied over the weld on one side of the cylinder, on
other side when colored paraffin or similar Product is applied over the weld, no colored spot
724
shall appear on the whitewash before 4 h. if any colored spots appear before 4 h. weld shall
be repaired and retested.
 Specials and fittings for PSC pipes shall be made out of steel plate fabricated to the required
dimensions and given a coating of cement mortar inside and outside and shall be as per the
specifications below:
 These specials shall be suitable for fixing PSC pipeline and shall conform to the requirements
of IS: 784 and IS: 7322.
 The steel for fabricated steel plate fittings is cut, shaped and welded so that the finished has
the required shape and interior dimensions. Adjacent segments shall be jointed by means of
lap or butt welding.
 The steel used for manufacturing of specials shall conform to IS: 2062 The specials
shall be lined inside and outside with 25mm thick cement mortar, reinforced with 50X50mm
weld mesh of specified gauge. The cement mortar in side shall be 1:1.5 (1 part cement: 1.5
part sand) and cement mortar outside shall be 1:2 (1 part cement: 2 part sand).
 All specials shall be hydrostatically tested before using as per Clause 8 of IS:7322. In case of
specials manufactured at site, they shall be tested by penetration oil or other approved means.
 All the specials shall be tested for hydrostatic pressure as specified for PSC pipe and to the
pressure specified for pipes in the reaches where the specials are fitted. All fittings shall be
inspected by the Engineer at the place of manufacture, or at site. Engineer, testing and
making of the fittings. The contractor is fully responsible for any defects in manufacturing
not conforming to IS Specifications.
 All defective specials shall be replaced by the Contractor free of cost.
 Extreme care shall be taken while carting the specials to site, so that inside or outside
coating is not damaged. If damages are observed the Contractor shall have to make it good at
his cost.

• Measurement
The Specials of pipes as laid or fixed shall be measured in Kilogram correct to a gm as

• Payment
of respective WUAs.
725

726
12.31 Hydraulic testing of Pre-Stressed Cement Concrete Pipes with rubber ring
Joints (Item No. LIPDN 40)
Hydraulic testing of Pre-Stressed Cement Concrete Pipes with rubber ring joints to specified
pressure including cost of all materials and labour and water for testing for the length up to 1
km., using reciprocating type pumps which should be able to provide specified test pressure
gauges and other necessary equipments, labour, operation charges, etc. required for testing.
The rate under this item shall also include cost of retesting, if necessary.

This specification covers the requirements for hydraulic testing at works and site Pre-Stressed
Cement Concrete Pipes used for water supplywith rubber ring joints to specified pressure
including cost of all materials and labour and water for testing for the length up to 1 km.,
using reciprocating type pumps.
•Field Testing of Pipeline system

hydrostatic test performed by filling the pipeline with water and raising the pressure to the
selected test pressure and maintaining this for a sufficient period to allow for absorption of
water by the pipe material.
AS per I.S.784, the test pressure should be 1.5 times design working pressure.
• Test procedure- Each section should be properly sealed off, preferably with special
stop secured by adequate anchors. The thrust on the stop ends should be calculated on the full
socket internal diameter and the anchors designed to resist it. It may often be economical to
provide a concrete anchor block of couple of pipes laid and earth tamped around which has
subsequently to be demolished rather than risk movement of the stop ends during testing.
Hydraulic jacks may be inserted between the temporary anchors and stop ends in order to take
up any horizontal movement of the temporary anchor.
• All permanent anchors should be in position and, if of concrete, should have developed
adequate strength before testing begins. The section under test should be filled with water,
taking care that all air is displaced either through vents at the high points, or by using a swab.
After filling, the pipeline should be left under operating pressure for period in order to achieve
conditions as stable as possible for testing. The length of this period will depend upon many
factors such as initial permeability, absorption, movement of the pipeline under pressure and
the quantity of air trapped.
• More water should be pumped in from a calibrated container until the required test
pressure is reached. The test pressure should be maintained throughout the test by means of
continuous pumping. The rate of loss of water from the container should be determined at
regular intervals. The generally accepted standard for absorbent pipelines such as PSC pipes
is3 liter per millimeter of pipe diameter per kilometer of pipeline per day for each 30 meter
head-of pressure applied.
Leak Detection -If the test is not satisfactory, the fault should be found and
rectified. Where there is difficulty in locating a fault, the section under test
should be subdivided and each part tested separately. If any leakage is found
during testing of pipeline, Contractor will have attend the same immediately
and rectify at his cost. If Contractor fails to rectify the defect, the entire length
727
of pipeline between two adjacent outlets shall be rejected. If any intermediate
e-payment is made to the Contractor for portion under rejection, the same shall
be recovered from the outstanding dues of the Contractor.
• Final Testing –After all sections have been jointed together on completion of
section testing, a test on the complete pipeline should be carried out. This test
should be carried out at a pressure not less than the working pressure of the
pipeline, care being taken to ensure that the pressure at the lowest point in the
pipeline does not exceed the maximum. During the test, an inspection should
be made of all work which has not been subjected to sectional tests.
Modalities of PMC / TPI / QC Inspection shall be separately decided and
given by Engineer In-charge. Project management consultants (PMC) should
have approved laboratories certification or collaboration with N.A.B.L.
(National Accreditation Board for Testing and Calibration Laboratories) Third
party Inspection can be done form any one of the following services or from
3 S.G.S, Mumbai
5 VJTI, Mumbai
728
laboratory assistants, labors and well-equipped laboratory for taking necessary
charge. Following minimum persons shall be employed by the contractor at
work site For Quality Assurance.

2 Laboratory Assistants (Twevlth Pass with Science Two to Four

(One for each

L.A.)
 Following minimum equipments shall be available in the field laboratory setup by

the contractor.
729

for Sand & Metal.

 The materials, mixes and any other arrangements, including labours, shall be supplied by the
his representative /QC present onsite. The contractor or his authorized representative shall
 The test of the pipe line in the field shall be carried out after the stretch of suitable length of
line is laid.
 Testing shall be carried out in the following manner. The pipe line shall be subjected to
hydraulic test in full length or in part as may be found necessary.
 The pipes shall be subjected to a test pressure of 1.5 times the actual working pressure
expected in the pipeline as per hydraulic design in the strip under observation. In case of leak
anywhere in the field joints, same shall be repaired entirely at the cost of the contractor
which shall include cost of excavation repairs etc.
 The contractor shall provide skilled and unskilled labour free of cost for departmental check
of the work.
 After all sections have been jointed together on completion of section testing, a test on the
complete pipeline should be carried out. This test should be carried out at a pressure not less
730
than the working pressure of the pipeline, care being taken to ensure that the pressure at the
lowest point in the pipeline does not exceed the maximum.
 Work of PDN shall be inspected, tested and certified by PMC / TPI / QC. Modalities of PMC
 All materials before being utilized in works shall be inspected and tested, by the Engineer In-
 testing of construction materials, pipes are required as per the detailed specifications or
selected by the Engineer-in-Charge.

• Measurement
The Hydraulic Testing of pipes as laid or fixed shall be measured in Kilometers
correct to a m. Specials shall be excluded and measured in running meters or numbers
as specified by Engineer-in-charge and paid for separately under the relevant item.
The portion of the pipe overlapped at the joints shall not be included in the length of
pipe work. Excavation, refilling, anchor blocks, thrust blocks wherever required shall
be measured and paid for separately under relevant items of work.

• Payment
of respective WUAs.
i. After Successful Operation and Maintenance for First year-2%

ii. After Successful Operation and Maintenance for Second year-2%
iii. After Successful Operation and Maintenance for Third year-2%
iv. After Successful Operation and Maintenance for Fourth year-2%
v. After Successful Operation and Maintenance for Fifth year-2%
----------***----------
731
Note
• During rotation period, once in every year, the Contractor shall perform hydraulic test
to the satisfaction of Engineer In-charge to verify the flow of designed discharge,
detect or confirm any leakage in the system and rectify at his own cost. The testing
shall preferably be conducted jointly with members of WUA/representative of
Engineer In-charge, technical representative of contractor and any other stake holder.
• During the O & M period, contractor shall give training to the members of WUA
about O & M of PDN work and its efficient use and protection of the system from any
damages.
• The contractor shall prepare a detail map of the permanent marking along the
alignment of pipe and submit the same to Engineer In-charge. The Engineer In-charge
shall verify and endorse the location of the marking and handover these signed maps
as a permanent record to WUA. Along with this, the detailed Geotagged map of laid
pipeline shall also be handed over to WUA.
• In association of the members of WUA, the Engineer In-charge shall confirm the
release of designed discharge through every outlet before handing over. In case of any
short fall or defect, it should be made good from the contractor at his own cost.
732
SPECIFICATION FOR BAR WRAPPED STEEL CYLINDER PIPES (BWSC)
12.32 Providing and supplying Bar Wrapped steel cylinder pipes (Item No.
LIPDN 41 )
Providing and supplying Bar Wrapped steel cylinder pipes, conforming to IS-15155-2002
(suitable for overlapping steel welded joint or butt welded steel joints) of following class and
diameter including cost of all material and labour required, inspection charges, transportation
to stores, transit insurance, loading, unloading and stacking excluding GST levied by GOI &
GOM in all respect, etc. complete.

This Specifications covers the requirements of bar / wire wrapped steel cylinder pipes with
mortar lining and coating with nominal internal diameter in the range of 250 mm to 1600 mm

 Introduction :
Bar/Wire wrapped steel cylinder (BWSC) pipe comprises of a welded steel sheet cylinder
with steel socket & spigot rings welded to its ends, lined with centrifugally applied cement
mortar within the steel cylinder. Reinforcement consisting of continuous steel bars/wire
helically wound around the outside of the cylinder is subsequently coated with dense cement
mortar.
The Contractor shall provide on-site training on BWSC pipe laying, jointing, testing and
should provide technical manual on BWSC Pipes including precautions to be taken during
733
The manufacturing, testing, supplying, jointing, welding and testing at work site of BWSC
pipes shall comply with all currently applicable statutes, regulations, standards, and Codes. In
cases, the latest revision of the Codes shall be referred to. If requirements of this specification
conflict with the requirements of the standards/ Codes, this specification shall govern. Other
codes not specifically mentioned here but pertaining to the use of BWSC pipes form part of
these specifications.
IS: 15155 Specifications for Bar/Wire Wrapped Steel Cylinder pipes
IS: 7322 Specifications for Specials for Steel Cylinder Reinforced Concrete pipes
IS 383 Specifications for coarse & fine aggregates from natural sources for concrete
IS 432 Specifications for Mild steel & medium steel bar/wire for Concrete
Part 1&2 Concrete.
 Raw Materials
Raw materials used to manufacture BWSC Pipes are cement, aggregates, water, admixture,
steel reinforcement, Steel plates. .
• Cement
The cement used in the manufacture of BWSC pipes shall conform to one of the
following.
• 43/53 grade Ordinary Portland Cement conforming to IS:8112/IS 12269
• Rapid Hardening Portland cement conforming to IS: 8041
• Portland Slag cement (with not more than 50% slag) conforming to IS: 455
• Sulphate Resisting Portland Cement conforming to IS: 12330
• Aggregate
734
• Water
The water used in the preparation of concrete mix shall be clean and free from
harmful or injurious compounds such as acids, alkali, oil, organic material or other
substances and shall conform to the requirements of mixing water as per IS : 456.
• Admixtures
admixture containing chlorides in any form shall be prohibited the admixtures shall
conform to IS 9103.
• Steel Reinforcement.
The reinforcement steel Bar/wire used for manufacturing BWSC Pipes shall conform
to IS: 432.
• Steel plates for Cylinder, Joint Rings and Specials.

Steel plates for Cylinder, Joint Rings and Specials shall conform to IS:2062.

The manufacturing of pipes & specials for BWSC pipes shall be as per IS 15155.
Various steps involved in pipe manufacturing process are as given below.
• Fabrication and hydrostatic testing of steel cylinder as per required size.

• Welding of steel socket & spigot rings to end of steel cylinder.
• Placing of rich cement mortar lining in the core by centrifugal method. ( minimum
cement content- 540kg/m3 , minimum water cement ratio – 0.42, minimum
compressive strength of cement mortar at 28 days-35 N/mm2, minimum compressive
strength of cement mortar at the time of wrapping of bar/wire -10 N/mm 2)
• Spiral widening of circumferential reinforcing bar/wire around the cylinder.
• Rich cement mortar out coating (Cover coating) on pipe (shall preferably be applied
within 16 hours after the bar/wire is wound). (minimum cement content- 540kg/m 3 ,
minimum water cement ratio – 0.27, minimum compressive strength of cement mortar
at 28 days-35 N/mm2).
• Curing of concrete.
735
Cross-section of BWSC Pipe Joint
BWSC pipe shall be designed to withstand the combined effects of internal water pressure &
external loads. Design of BWSC pipes shall be site specific as internal water pressure will
separately for sampling and evaluation, for conformity to the requirements of IS 15155. Scale
of sampling shall be as given following Table No.1
Table No.1 Scale of Sampling and No. of Acceptable defective tests

No of Hydrostatic Coating Hydrostatic Diamensi Permeabil

Joint rings
pipes testing of thickness test of pipe onal test ity test
dimensions
in lot cylinder at factory (1)
* ** * ** * ** * ** * ** * **
Upto All All 3 1 3 NI 3 NI
NIL NIL NIL NIL
50 L L
51- All All 5 1 5 NI 5 NI
NIL NIL NIL NIL
100 L L
101- All All 8 2 8 NI 8 NI
NIL NIL NIL NIL
300 L L
300- All All 13 2 13 NI 13 NI
NIL NIL NIL NIL
500 L L
500- All Nil All Nil 26 1 4 Nil 26 1 26 1
1000
(1) Includes socket and spigot

* Number of samples
736
** Number of defective samples
 Pre-Delivery Testing Of Pipes

Pipe selected as per sampling criteria mentioned in above para are subject to following tests
before delivery from factory.
• Steel cylinder test
• Dimensions - Length, Internal diameter, Core thickness, straightness and finish.
• Hydrostatic Factory Test
• Permeability Test on Coating
• Mortar soundness test
• Steel Cylinder Test
During manufacturing, each steel cylinder with steel and spigot rings welded on shall
be subjected to water pressure which stresses the steel to at least 140 N/mm 2but not
more than 175 N/mm2. While under stress, the assembly, especially welds shall not
show any leakage. If any leakage is found, assembly shall be repaired and whole
assembly retested.
• Dimensions
• Length -
Length of Pipe shall be 4m to 8m.
• Nominal internal diameter of the pipes, minimum wall thickness and minimum
thickness of cement mortar lining shall be as per following Table no.2
Table 2 Nominal Internal Diameter, Minimum wall thickness and Minimum thickness
of cement mortar lining
(Reproduced fromIS 15155)
Nominal Minimum Minimum Minimum steel Minimum
Internal wall Thickness of cylinder Thickness of
Diameter of Pipe thickness cement thickness joint rings
(mm ) (mm ) mortar (mm ) (mm )
lining
(mm )
250 40 15 1.6 5.0
300 40 15 1.6 5.0
400 40 15 1.6 5.0
500 45 20 1.6 5.0
600 45 20 2.0 5.0
700 45 20 2.0 5.0
737
Nominal Minimum Minimum Minimum steel Minimum
Internal wall Thickness of cylinder Thickness of
Diameter of Pipe thickness cement thickness joint rings
(mm ) (mm ) mortar (mm ) (mm )
lining
(mm )
800 45 20 2.0 5.0
900 45 20 2.5 5.0
1000 45 20 2.5 7.0
1100 50 22 4.0 7.0
1200 50 22 4.0 7.0
1300 50 22 4.0 8.0
1400 50 22 4.0 8.0
1500 50 22 4.0 8.0
1600 50 22 4.0 8.0
• The deviation from straight line taken between two points one meter apart, along
the pipe barrel shall not exceed 5mm.
• The pipe shall be free from local depressions or bulges greater than 5mm extending
over a length, in any direction.
• Hydrostatic Factory Test

The finished pipe shall be subjected to factory pressure test. The pipe shall be
tested in accordance with IS 3597.One in 50 pipes shall be subjected to an internal
hydrostatic test. Should a pipe fail the test, then a further two pipes from the same
batch of 50 shall be tested. If both pipes pass, then the batch shall be accepted. If one
or both pipes fail then the batch shall be rejected or each pipe in the batch shall be
tested for individual approval. The pipe shall be tested for a period of 3 min. During
the test the pipe shall be absolutely water-tight and show no leaks, weeping or defects
considered detrimental to the pipe’s performance. No crack in the external surface
shall be wider than 0.5 mm on a length exceeding 300 mm using a feeler gauge.
738
Permeability Test on Coating
method described in IS 3597 shall not exceed 2 cm3 at the end of two hours and the final
permeability between fourth and fifth hours shall not exceed 0.3 cm 3. When a higher result
is obtained, the test shall be repeated on twice the number of pipes originally tested and the
lot shall be accepted, if all pipes pass the test. Where retest is not satisfactory, all pipes
from that lot may be tested individually and only those with satisfactory results shall be
accepted. No additional treatment of any type shall be allowed on the pipe before
permeability test is taken. The test shall be done immediately after the hydraulic factory
test. In case this is done later, then the pipe has to be kept wet for 48 hrs prior to test.
Mortor soundness test

After the mortar coating is cured and prior to transport, the coating on each pipe shall be
checked for delamination and hollows by tapping the exterior with hammer having head of
mass of not more than 0.5 kg. Any hollows or drumming areas detected by sounding shall
be repaired by approved method.
• Manufactures name or trademark.
• Pressure rating.
• Nominal diameter
• Lot/batch No. of manufacturer.
• BIS certification mark.
• Third Party Certification mark for each lot
• Name of Department/Project for pipe which pipes are manufactured.
• Any other important matter that the manufacturer or purchaser deems fit to be
inscribed.
Following precautions shall be taken during transportation of pipes.
• The vehicle shall have side supports approximately spaced 2 m apart, and the pipes
shall be secured effectively during the transportation. All posts shall be flat with no sharp
edges.
slowly and with every reasonable precaution against damage. Any portion of the lining,
coating that may become damaged shall be repaired with polymer Mortar.
739
• All pipes shall be loaded in trucks by mechanical crane/ tripod and unloaded carefully
using crane/ tripod. No unloading using crow bars or on tires will be allowed in any case.
Rubber belt may be used instead of crow bars or chains.
such a way that they are secure and that no movement can take place on the vehicle during
transit. The same care is needed if pipes are to be transferred from one vehicle to another,
however, short the journey may be.
• Un-loading of pipes should be carried out by means of chain block with shear legs or
crane of adequate capacity, using properly designed slings and spreader beams or specially
designed lifting beams. Slings should be placed around the circumference of the pipe and
should not be threaded through the pipe bore' as the latter method may damage the jointing
surfaces. For the same reasons, hooks located in the ends of the pipes should not be used.

damages to pipes.
succeeding tiers.
required.
740
 Valves
various location.
• Air Valve :
• Scour Valve :
• Control Valve :

• Sliding Stem
 Globe valve
• Rotary
 Butterfly valve
 Ball valve
• Other
 Pinch valve
 Diaphragm valve

conducted on random samples of pipes collected from site. These tests shall be as per those
given in above para.
741
charge. Project management consultants (PMC) should have approved laboratories
• S.G.S, Mumbai
• Vishveshvaraya National Institute of Technology, Nagpur
• VJTI, Mumbai
otherwise specified. Labors for collecting samples and transportation of the samples
by the contractors.
the work, materials and finished item to the standard as determined by the
laboratory tests or to take follow up action to rectify the quality.
742

charge.
Quality Assurance.

2 Laboratory Assistants(Twevlth Pass with Science Two to Four
subject with 2 year experience in testing of material) (As per work)
(One for each
L.A.)
• Following minimum equipments shall be available in the field laboratory setup by

the contractor.

It is the responsibility of the contractor to assure the desired quality of work.

Contractor’s cost. The other test for mortar, concrete, sand, coarse aggregates etc.
shall be carried out in field laboratory set up by the contractor in presence of
quality control representative at contractors cost. Contractor shall through this
• The materials, mixes and any other arrangement s, including labours, shall be
supplied by the contractor .The samples for testing shall be taken in the presence of
Engineer-in-Charge or his representative /QC present onsite. The contractor or his
authorized representative shall have a free access in these laboratories, to get
743
specification.
of work.
• Pre delivery testing of pipes shall be carried out by the contractor in the presence
of representative of Engineer-In-charge /WRD/QC/TPI.. like Steel cylinder test ,
Dimensions - Length, Internal diameter, Core thickness, straightness and finish,
Hydrostatic Factory Test, Permeability Test on Coating and Mortar soundness test.
Party Certification mark for each lot , Name of Department/Project for which
pipes are manufactured. Any other important matter that the manufacturer or
purchaser deems fit to be inscribed etc.
• While transporting pipes, vehicle shall have side supports approximately spaced
2 m apart, and the pipes shall be secured effectively during the transportation. All
posts shall be flat with no sharp edges.
• Pipes manufactured at factory are to be transported to the site of work directly or
stacked suitably and neatly along the alignment/ road side/elsewhere near by the
work site, as directed by the Engineer.
• All pipes shall be loaded in trucks by mechanical crane/ tripod and unloaded
carefully using crane/ tripod. No unloading using crow bars or on tires will be
allowed in any case. Rubber belt may be used instead of crow bars or chains.
such a way that they are secure and that no movement can take place on the
vehicle during transit. The same care is needed if pipes are to be transferred from
one vehicle to another, however, short the journey may be.
• Un-loading of pipes should be carried out by means of chain block with shear legs
or crane of adequate capacity, using properly designed slings and spreader beams
or specially designed lifting beams. Slings should be placed around the
circumference of the pipe and should not be threaded through the pipe bore' as the
744
latter method may damage the jointing surfaces. For the same reasons, hooks
located in the ends of the pipes should not be used.
succeeding tiers.
required.

 Measurement
The net length of pipes as laid or fixed shall be measured in running meters correct to
 Damages during transit, handling, storage will be to the Contractor’s account and
745
 Payment
of respective WUAs.
 After Successful Operation and Maintenance for Second year-2%
 After Successful Operation and Maintenance for Third year-2%
 After Successful Operation and Maintenance for Fourth year-2%
 After Successful Operation and Maintenance for Fifth year-2%

----------***----------
746
12.33 Lowering, laying and jointing in proper grade and alignment Bar (Item No.
LIPDN 42)
Lowering, laying and jointing in proper grade and alignment Bar wrapped steel cylinder pipes
with couplings & gasket including cost of conveyance from stores to site of works, all labour
involved, etc. complete (for all class of pipes)

testing at works and site of bar / wire wrapped steel cylinder pipes used for water supply.

The Contractor shall clear the entire area required for setting out. All tree
stumps, roots, brushwood, rubbish of all kinds, loose stones and all other
objectionable materials shall be removed by the Contractor. Buried irrigation pipeline,
and other structure, if any, shall be removed by the Contractor. The ownership of all
the usable material, so removed from clearing site and/or excavation shall rest with the
Engineer In-charge. Useful material shall be stacked as directed. The Contractor shall
dispose off all un-useful materials as directed by the Engineer In-charge.
• Demarcation
All materials such as pegs, bamboos and strings and templets for marking out
slopes, and labour required for line out should be provided by the Contractor at his
own cost. The center line of excavation shall be clearly marked by pegs or by stones
at each chain or change of direction or at shorter intervals on curves, in the
beginning. The final line out will be done by fixing reference stone at suitable
distances on either side of the center line, beyond the canal edges so that they are not
disturbed during the construction period. The position of these stones will be marked
on the cross section.Contractor shall provide and maintain the quarry roads and
temporary roads required for construction activity at his own cost.
 Benchmarks fixed by the Survey of India and temporary benchmarks
established by the Engineer In-charge in vicinity of PDN work will serve as control
points for these works. The Contractor shall establish sufficient number of reference
benchmarks for facilitating setting out of work and taking levels for the purpose of
measurements.
 Before starting any work, the Contractor shall erect reference benchmarks,
reference lines and check profiles at convenient locations approved by the Engineer
In-Charge. The benchmark concrete block shall be 200mm x200mm x600mm with
400mm embedded in the firm ground and 200 mm projecting above ground. The
word ‘BM’ showing value of R.L. in ‘m’ shall be conspicuously carved and painted
on the benchmark.
 The check profile shall be located 30m apart or closer as directed by the
Engineer In-Charge so as to ensure execution of all slopes, steps and elevations to the
profile or profiles indicated in the approved drawings. All important levels and all
control points with respect to benchmarks and reference lines shall be fixed and
747
correlated by the Contractor. The Contractor is fully responsible for maintaining all
setting out work & Benchmark established by Engineer-In-charge.
 All materials, labour and equipments (theodolites, levels, distometre, etc.) for
setting out works including construction of benchmarks in concrete, reference lines,
check profiles and surveys as may be required at the various stages of construction
shall be supplied by the Contractor at his cost. For this following numbers of
minimum equipments shall be provided and maintained in good working condition
by the Contractor.

2. Theodolites (Accuracy1second) 1No.
3. Levels 2Nos.
4. Staves 4Nos.
made available in advance of starting of the work. All equipment shall be
maintained, repaired and got tested and certified as and when required for its
accuracy from the standard test houses or from the manufactures and to the

drawing or as directed by Engineer In -charge. Contractor must assume all
mm.
Engineer In-charge. Un-useful material from excavation shall be deposited in spoils
as and where directed by Engineer-In-charge.
trench. When the drain/nalla bed is higher than the sub-soil water level met with,
the bailing out by suitable means of pumping shall be resorted to for dewatering
sub-soil water below the drain/nalla bed level. No distinction shall be made as to
whether the material being excavated is dry, moist, wet or slushy. The Contractor
shall have to excavate the PDN pipe trench and structure in under water level
conditions also i.e. under wet/slushy condition after providing sufficient
arrangement of dewatering. The material excavated under water level condition
which requires intermediate stacking for drying shall have to be re-handled. No
extra payment for efforts for drying out of soil, re-handling of dry soil, etc. shall be
given. No payment for extra efforts for excavation under this condition shall be
made.
748
• Over excavation performed by the Contractor for any purpose or reason, except for
additional excavation as may be directed by the Engineer-In-charge, shall be
excavation using the material as directed by the Engineer In- Charge shall also be at
the cost of the Contractor.
and structure shall be over excavated to the extent as directed by the Engineer In
soil to be placed in uniformly compacted layers as directed by the Engineer In
 Laying of Pipes
While laying of BWSC pipe, all precaution as mentioned in IS 783 shall be taken.
Concrete pipes have to be properly handled, bedded & back filled, if they have to carry
the full design loads safely.
• Pipes should be lowered into the trench with tackle suitable for the weight of pipes,
such as well designed shear slings with chain block or mobile crane.
• While lifting, the position of the sling should be checked when the pipe is just clear
• Expansion joints shall be provided for buried lines at maximum interval of 100m, if
• Each pipe shall be thoroughly checked for any damages before laying and only the
laying in rocky area, 150 mm compacted fine sand bedding under and around pipe
needs to be provided.
• Jointing of pipes shall be done as per procedure mentioned in IS 783. The sections
• Jointing process of BWSC pipe consist of following steps.
749
 Aligning of points at joint locations.
 Field welding of socket ring at joint externally.
 Fixing of diaper with steel strap at joint location.
 Pouring of cement mortar through diaper at joint location.
 Filling inside of joints by cement mortar.
• The basic requirements for all joints are as enumerated below.
 Cleanliness of all parts, particularly joint surface;
 Correct location of components;
 Centralization of spigot within socket;
 Provision of the correct gap between the end of the spigot and the back of the
socket

Engineer In-charge.
 Engineers India Limited, Mumbai
 R.I.T.E.S. (Rail India Technical Economics Services) Mumbai
 S.G.S, Mumbai
 Vishveshvaraya National Institute of Technology, Nagpur
 VJTI, Mumbai
 CWPRS (Central Water & Power Research Station), Pune
 CIPET (Central Institute of Plastics Engineering & Technology)
 All materials before being utilized in works shall be inspected and tested, by
the Engineer In-charge or his representative/QC. The nature of testing and
shall be provided free of cost by the contractor. Also electricity, fuel, water curing
tank and stores etc. shall be provided free of cost by the contractors.
 The materials shall be tested in QC laboratory or at any other place directed by
750
Contractor’s responsibility to produce on the work, materials and finished item to
the standard as determined by the laboratory tests or to take follow up action to
rectify the quality.
 Testing charges for testing of Cement, TMT bars, all types of pipes and
specials including cost of samples and its collection shall be borne by the
Contractor.
 The Contractor shall make suitable arrangements to see that one of his

charge.
Quality Assurance.

(One for each
L.A.)

the contractor.
It is the responsibility of the contractor to assure the desired quality of work.

751
Contractor’s cost. The other test for mortar, concrete, sand, coarse aggregates etc.
shall be carried out in field laboratory set up by the contractor in presence of
• The materials, mixes and any other arrangement s, including labours, shall be
of Engineer-in-Charge or his representative /QC present onsite. The contractor or
results will be considered as authentic and binding on the contractor.
per specification.
quality of work.

752
used in back filling. If such usable material is in excess of the requirement of
Engineer In-charge.
structure shall be over excavated to the extent as directed by the Engineer In-Charge
and such over excavated section shall be filled with suitable murum type soil to be
 Before the pipes are lowered and laid in position the contractor shall see that the
 While laying of BWSC pipe, all precaution as mentioned in IS 783 shall be taken.
drawings.
 While lifting, the position of the sling should be checked when the pipe is just clear
 Bedding requirements are minimal due to rigid nature of pipe. However, while laying
in rocky area, 150 mm compacted fine sand bedding under and around pipe needs to
be provided.
 Jointing of pipes shall be done as per procedure mentioned in IS 783. The sections
 Jointing process of BWSC pipe consist of following steps.
 Aligning of points at joint locations.
753
The basic requirements for all joints are as enumerated below.
 Cleanliness of all parts, particularly joint surface;

 Correct location of components;
 Centralization of spigot within socket;
 Provision of the correct gap between the end of the spigot and the back of the
socket
 The backfill material shall be placed carefully and spread in uniform layers of not
more than 15cm thickness, with the first layer watered and compacted by stamping or
by mechanical means. The backfill shall be brought up as uniformly as practicable on
both sides of pipe to prevent unequal loading.
etc. shall be used for refilling trench up to 300mm above top of pipe. If sufficient
quantity of suitable (Sharp edge stone free) excavated earth is not available, the
trench shall be filled by borrowed gravel material up to 300 mm above top of
 Pipe embedment backfill shall be stone-free excavated material.
 The trench shall be refilled so as to built-up the original ground level
 The moisture content of the earth fill placed against the rock or the structure shall be
on higher/lower side of OMC by about 2% or so, to allow it to be compacted. Profuse
watering shall be done to pervious materials (sand) before compaction as per
instruction of the Engineer-in-Charge.
 Compaction at junction of earthwork and backfill around the structure shall be carried
 The contractor shall establish the sufficient number of reference blocks for permanent
the field boundaries so as they will not be disturbed during the agricultural activities
of the farmers.
 For the desired quality of work. Whenever the testing of construction materials, pipes
754
 Measurement
The Lowering, Laying & Jointing of pipes as laid or fixed shall be measured in running
meters correct to a cm. Specials shall be excluded and measured in running meters or
numbers as specified by Engineer-in-charge and paid for separately under the relevant item.
The portion of the pipe overlapped at the joints shall not be included in the length of pipe
work. Excavation, refilling, anchor blocks, thrust blocks wherever required shall be measured
and paid for separately under relevant items of work.

 Payment
 The break up to payment for supplying, laying, jointing & hydrostatic
testing of pipeline shall be as under:-
 80% of the payment will be released after supplying, lowering, laying, jointing
 Balance 10% of the payment will be released after satisfactory hydraulic
testing of pipeline and backfilling of trenches.
 Remaining 10% amount will be withheld and it will be released after
successful maintenance and operation for a period of five years after
commissioning of work of respective WUAs.
 After Successful Operation and Maintenance for First year-2%
 After Successful Operation and Maintenance for Second year-2%
 After Successful Operation and Maintenance for Third year-2%
 After Successful Operation and Maintenance for Fourth year-2%
 After Successful Operation and Maintenance for Fifth year-2%

Chairman of WUA shall be binding for annual release of this amount and
755
12.34 Providing and supplying ISI mark Bar wrapped steel cylinder pipes (Item
No. LIPDN 43)

Providing and supplying ISI mark Bar wrapped steel cylinder pipes fitting/specials including
loading, unloading, transportation up to departmental store, stacking excluding GST levied by
GOI & GOM in all respect etc. complete.
This specification covers the requirements for providing and supplying ISI mark Bar wrapped
steel cylinder pipes fitting / specials including loading, unloading, transportation up to
departmental store, stacking excluding GST levied by GOI & GOM in all respect etc.
complete.
12.34.3 Site preparation:

 Introduction :
Bar/Wire wrapped steel cylinder (BWSC) pipe comprises of a welded steel sheet cylinder
with steel socket & spigot rings welded to its ends, lined with centrifugally applied cement
mortar within the steel cylinder. Reinforcement consisting of continuous steel bars/wire
helically wound around the outside of the cylinder is subsequently coated with dense cement
mortar.
The Contractor shall provide on-site training on BWSC pipe laying, jointing, testing and
should provide technical manual on BWSC Pipes including precautions to be taken during
756
The manufacturing, testing, supplying, jointing, welding and testing at work site of BWSC
pipes shall comply with all currently applicable statutes, regulations, standards, and Codes. In
cases, the latest revision of the Codes shall be referred to. If requirements of this specification
conflict with the requirements of the standards/ Codes, this specification shall govern. Other
codes not specifically mentioned here but pertaining to the use of BWSC pipes form part of
these specifications.
IS: 15155 Specifications for Bar/Wire Wrapped Steel Cylinder pipes
IS 383 Specifications for coarse & fine aggregates from natural sources for concrete
IS 432 Specifications for Mild steel & medium steel bar/wire for Concrete
Part 1&2 Concrete.
 Raw Materials
Raw materials used to manufacture BWSC Pipes are cement, aggregates, water, admixture,
steel reinforcement, and Steel plates.
• Cement
The cement used in the manufacture of BWSC pipes shall conform to one of the
following.
13. Sulphate Resisting Portland Cement conforming to IS: 12330
757
• Aggregate
• Water
The water used in the preparation of concrete mix shall be clean and free from
harmful or injurious compounds such as acids, alkali, oil, organic material or other
substances and shall conform to the requirements of mixing water as per IS : 456.
• Admixtures
admixture containing chlorides in any form shall be prohibited. The admixtures shall
conform to IS 9103.
• Steel Reinforcement.
The reinforcement steel Bar/wire used for manufacturing BWSC Pipes shall conform
to IS: 432.
• Steel plates for Cylinder, Joint Rings and Specials.

Steel plates for Cylinder, Joint Rings and Specials shall conform to IS:2062.

The manufacturing of pipes & specials for BWSC pipes shall be as per IS 15155.
Various steps involved in pipe manufacturing process are as given below.
• Fabrication and hydrostatic testing of steel cylinder as per required size.

• Welding of steel socket & spigot rings to end of steel cylinder.
• Placing of rich cement mortar lining in the core by centrifugal method. ( minimum
cement content- 540kg/m3 , minimum water cement ratio – 0.42, minimum
compressive strength of cement mortar at 28 days-35 N/mm2, minimum
compressive strength of cement mortar at the time of wrapping of bar/wire -10
N/mm2)
• Spiral widening of circumferential reinforcing bar/wire around the cylinder.
• Rich cement mortar out coating (Cover coating) on pipe (shall preferably be
applied within 16 hours after the bar/wire is wound). (minimum cement content-
540kg/m3 , minimum water cement ratio – 0.27, minimum compressive strength of
cement mortar at 28 days-35 N/mm2).
• Curing of concrete.
758
Cross-section of BWSC Pipe Joint
BWSC pipe shall be designed to withstand the combined effects of internal water pressure &
external loads. Design of BWSC pipes shall be site specific as internal water pressure will
 Valves
various locations.
• Air Valve :
three areas: firstly, in the waterfilled stage of the pipeline, filled with water by a
certain velocity, the air valve can discharge the remained gas in the pipe; secondly,
at the normal working stage, the air valve can discharge the small amount of gas
gathered in the pipe timely; finally, during the pump failure or maintenance stages,
the air valve will replenish the gas into the pipe to break the vacuum. According to
the orifice size, displacement and work pressure, air valve is divided into high
pressure trace exhaust valve, low pressure air release valve and combined air valve.
• Scour Valve :
Scour valves is frequently influenced by opportunities to dispose off the water.
• Control Valve :
759
1. Sliding Stem
 Globe valve
2. Rotary
 Butterfly valve
 Ball valve
3. Other
 Pinch valve
 Diaphragm valve

Work of PDN shall be inspected, tested and certified by PMC / TPI / QC. Modalities of
or collaboration with N.A.B.L. (National Accreditation Board for Testing and Calibration
Laboratories)
 Engineers India Limited, Mumbai
 R.I.T.E.S. (Rail India Technical Economics Services) Mumbai
 S.G.S, Mumbai
 Vishveshvaraya National Institute of Technology, Nagpur
 VJTI, Mumbai
 CWPRS (Central Water & Power Research Station), Pune
 CIPET (Central Institute of Plastics Engineering & Technology)
760

On award of contract, the Contractor will have to provide adequate quality assurance setup
including Quality Assurance Engineer backed with suitable laboratory assistants, labours
and well equipped laboratory for taking necessary field test required as per specifications
and as per instructions of Engineer in charge.
Quality Assurance.

(One for each
L.A.)

the contractor.

1. It is the responsibility of the contractor to assure the desired quality of work. Whenever the
761
presence of quality control representative at contractors cost. Contractor shall through this
2. The materials, mixes and any other arrangement s, including labours, shall be supplied by the
contractor .The samples for testing shall be taken in the presence of Engineer-in-Charge or his
representative /QC present onsite. The contractor or his authorized representative shall have a
free access in these laboratories, to get himself satisfied about procedures of testing etc. Even
if the contractor or his representative fails to remain present while collecting samples or
testing, the results will be considered as authentic and binding on the contractor.
3. Contractor shall provide all test reports of material used in the work as desired from the
4. Contractor shall submit the account of all materials brought for the work, which are necessary
for execution of work and any other data necessary to assess the quality of work.
5. If he fails to fulfil the above requirement, the required manpower for testing and field
• All fittings/specials shall be fabricated or moulded at factory only. No fabrication or

moulding will be allowed at site, unless specifically permitted by the Engineer-in-Charge.
• All materials before being utilized in works shall be inspected and tested, by the Engineer In-
• For the desired quality of work. Whenever the testing of construction materials, pipes are
 Measurement
The Specials of pipes as laid or fixed shall be measured in running meters correct to a cm as
specified by Engineer-in-charge and paid for separately under the relevant item. The portion
of the pipe overlapped at the joints shall not be included in the length of pipe work.
Excavation, refilling, anchor blocks, thrust blocks wherever required shall be measured and
paid for separately under relevant items of work.
762
Payment
• 80% of the payment will be released after supplying, lowering, laying, jointing and third party
inspection of pipes in one WUA area.
• Balance 10% of the payment will be released after satisfactory hydraulic testing of pipeline
• Remaining 10% amount will be withheld and it will be released after successful maintenance
and operation for a period of five years after commissioning of work of respective WUAs.

Chairman of WUA shall be binding for annual release of this amount and
----------***----------
763
12.35 Hydraulic testing of Bar wrapped steel cylinder pipes to specified pressure(Item No.
LIPDN 44)
Hydraulic testing of Bar wrapped steel cylinder pipes to specified pressure including cost of
all materials and labour and water for testing for the length up to 1 km., using reciprocating
type pumps which should be able to provide specified test pressure gauges and other
necessary equipments, labour, operation charges, etc. required for testing. The rate under this
item shall also include cost of retesting, if necessary.

This specification covers the requirements for hydraulic testing at works and site of Bar
wrapped steel cylinder pipes to specified pressure including cost of all materials and labour
and water for testing for the length up to 1 km., using reciprocating type pumps which should
be able to provide specified test pressure gauges and other necessary equipments, labour,
operation charges, etc. required for testing. The rate under this item shall also include cost of
retesting, if necessary.
 Field Testing of Pipeline system

• All pipelines should be tested before being brought into service. The test
should be a hydrostatic test performed by filling the pipeline with water and raising the
pressure to the selected test pressure and maintaining this for a sufficient period to allow
for absorption of water by the pipe material.
• AS per I.S.784 the test pressure should be 1.5 times design working pressure.
• Test procedure: Each section should be properly sealed off, preferably with special stop
secured by adequate anchors. The thrust on the stop ends should be calculated on the full
provide .a concrete anchor block of couple of pipes laid and earth tamped around which
has subsequently to be demolished rather than risk movement of the stop ends during
testing. Hydraulic jacks may be inserted between the temporary anchors and stop ends in
order to take up any horizontal movement of the temporary anchor. All permanent anchors
should be in position and, if of concrete, should have developed adequate strength before
testing begins. The section under test should be filled with water, taking care that all air is
displaced either through vents at the high points, or by using a swab.
After filling, the pipeline should be left under operating pressure for a period in order to
achieve conditions as stable as possible for testing. The length of this period will depend
upon many factors such as initial permeability, absorption, movement of the pipeline under
pressure and the quantity of air trapped.
More water should be pumped in from a calibrated container until the required test
pressure is reached. The test pressure should be maintained throughout the test by means of
764
regular intervals. The generally accepted standard for absorbent pipelines such as BWSC
pipes is 3 liter per millimeter of pipe diameter per kilometer of pipeline per day for each 30
meter head-of pressure applied.
• Leak Detection - If the test is not satisfactory, the fault should be found and rectified.
Where there is difficulty in locating a fault, the section under test should be subdivided and
If any leakage is found during testing of pipeline, Contractor will have to attend the
same immediately and rectify at his cost within. If Contractor fails to rectify the defect, the
entire length of pipeline between two adjacent outlets shall be rejected. If any intermediate
payment is made to the Contractor for portion under rejection, the same shall be recovered
from the outstanding dues of the Contractor.

• Project management consultants (PMC) should have approved laboratories certification
or collaboration with N.A.B.L. (National Accreditation Board for Testing and Calibration
Laboratories)
• Third party Inspection can be done form any one of the following services or from any
1. Engineers India Limited, Mumbai
2. R.I.T.E.S. (Rail India Technical Economics Services) Mumbai
3. S.G.S, Mumbai
4. Vishveshvaraya National Institute of Technology, Nagpur
5. VJTI, Mumbai
6. CWPRS (Central Water & Power Research Station), Pune
7. CIPET (Central Institute of Plastics Engineering & Technology)
All materials before being utilized in works shall be inspected and tested, by the Engineer
In-charge or his representative/QC. The nature of testing and periodical intervals at which
such testing is to be done etc. shall be as per the latest editions of relevant IS Codes and
determined by the Engineer In-charge. The day-to-day and periodical tests to be carried
out on materials mixes and placed concrete, mortar etc. shall be specified by the Engineer
In-charge from time to time and the Contractor shall provide free of cost all facilities
towards collections of samples etc. unless otherwise specified. Labours for collecting
samples and transportation of the samples to quality control authorities for test shall be
provided free of cost by the contractor. Also electricity, fuel, water curing tank and stores
etc. shall be provided free of cost by the contractors.
The materials shall be tested in QC laboratory or at any other place directed by the
Engineer In-charge. The Contractor shall obtain the test results from the concern authority
and the results given by such authorities shall be considered to determine whether all
materials, workmanship are of respective standard described in contract and in accordance
with the instructions of the Engineer In-charge. The Contractor’s representatives shall,
however, be given access to all operations and tests that may be carried out as aforesaid so
that he may satisfy himself regarding the procedure and methods adopted. It shall then be
the Contractor’s responsibility to produce on the work, materials and finished item to the
765
standard as determined by the laboratory tests or to take follow up action to rectify the
quality.
Testing charges for testing of Cement, TMT bars, all types of pipes and specials including
The Contractor shall make suitable arrangements to see that one of his representatives
Contractor, fails to keep his representative present at site at the time of taking samples or
fail to provide required labours and other equipment to collect the samples, the same shall
be taken by the Engineer In-charge, and the samples selected shall be considered as
authentic. The cost incurred by the Engineer-In-charge when the Contractor fails to
provide required men and materials for collecting samples and or their transport shall be
recovered from the Contractor.
 On award of contract, the Contractor will have to provide adequate quality

charge.
 Following minimum persons shall be employed by the contractor at work site for
Quality Assurance.

(One for each
L.A.)
 Following minimum equipments shall be available in the field laboratory setup by

the contractor.
 It is the responsibility of the contractor to assure the desired quality of work.

Whenever the testing of construction materials, pipes are required as per the detailed
specifications or otherwise required by the Engineer-in-Charge, the same shall be carried
out at the laboratory, selected by the Engineer-in-Charge at Contractor’s cost. The other
test for mortar, concrete, sand, coarse aggregates etc. shall be carried out in field
766
laboratory set up by the contractor in presence of quality control representative at
contractors cost. Contractor shall through this procedure assure the quality of work.
 The materials, mixes and any other arrangement s, including labours, shall be
supplied by the contractor .The samples for testing shall be taken in the presence of
Engineer-in-Charge or his representative /QC present onsite. The contractor or his
authorized representative shall have a free access in these laboratories, to get
 Contractor shall provide all test reports of material used in the work as desired from
specification.
of work.
If he fails to fulfil the above requirement, the required manpower for testing and field

 All pipelines should be tested before being brought into service. The test should be a
 The test should confirm to following conditions
component.
 Pipe systems should be hydraulically tested in lengths appropriate to the diameters and site
conditions. Pipelines longer than 800 m may require testing in sections. Preferably, the length
selected for test is between 300 m and 500 m.
 Testing should not take place until any concrete used for anchoring has fully cured (normally
72 h) and attained its required strength. Solvent cemented joints must be allowed to harden
for a minimum of 24 h before being subjected to test conditions.
 It is important to provide sufficient backfill over the main barrel of the pipe, to prevent
displacement and to maintain stable temperature conditions. Leave joints free for inspection.
 The test position should be located at the lowest point of the pipeline profile to encourage
expulsion of air as the pipe is being filled with water. Adequate air release mechanisms
should be located at all high points along the line.
 Before filling the pipeline, all line valves and air venting systems should be checked open. All
air must be removed from the system.
767
 Fill the system slowly. Water velocity must not exceed 0.6 m/s. Potable water pipelines
should be tested with potable water only. After charging, close all air valves and check proper
action of automatic valves.
 Allow the system to stabilize under a nominal pressure for a minimum of 2 hours. Apply
increase.
 The pressure should be increased till the specified pressure is reached at the lowest part of the
section. Maintain test pressure at this level, by additional pumping if necessary, for a period
of 1 hour.
 Close all valves and disconnect the pressurizing unit. No further water should be allowed to
enter the system for a further period of 1 hour.
 During the test period, carry out a visual examination of all joints and exposed connections.
 There should be no leakage in any part of the section.
 If there has been a decrease in pressure during this period other than due to leakage, the
original pressure is re-established by injecting a measured quantity of water into the section.
 The test is considered to be satisfactory if
 there is no decrease in pressure (a slight rise in pressure is also, possible due to changes in
ambient temperatures),
 the measured quantity of water required to reinstate the pressure to the original test pressure is
less than the ‘permissible maximum’ Q,
 Where, Q = 4.5 liters per 1.6 km per 25 mm of nominal bore per 30 m head of test pressure
per 24 hours.
 On completion of any test, the residual pressure should be released slowly and in a carefully
controlled manner.
 All defects revealed in the test should be rectified and the procedure repeated until a
 If any leakage is found during testing of pipeline, Contractor will have to attend the same
immediately and rectify at his cost. If Contractor fails to rectify the defect, the entire length of
pipeline between two adjacent outlets shall be rejected. If any intermediate payment is made
to the Contractor for portion under rejection, the same shall be recovered from the
outstanding dues of the Contractor.
 Third Party Inspection of PDN work shall be inspected, tested and certified by PMC/TPI/QC.
Modalities of PMC/TPI/QC Inspection shall be separately decided and given by Engineer-In-
charge.

 Measurement
The Hydraulic Testing of pipes as laid or fixed shall be measured in Kilometres correct to a
m. Specials shall be excluded and measured in running meters or numbers as specified by
 Payment
768
• 80% of the payment will be released after supplying, lowering, laying, jointing and third
• Balance 10% of the payment will be released after satisfactory hydraulic testing of pipeline
respective WUAs.
Chairman of WUA shall be binding for annual release of this amount
----------***----------
Note:
 Operation, Maintenance and Handing over of the System

• The contractor shall operate and maintain the complete pipe distribution network for the
period of 5 (five) years after commissioning. Out of this period, during last two years the
operation of the schemes shall be done by the contractor jointly along with WUA. On
completion of O & M period, the system shall be handed over to WUA
• On completion of every Irrigation season, the contractor shall flush the pipe line from its
tail flush valve so that any siltation, vegetation or obstruction is cleaned and pipe is able
to flow designed discharge for next season.
• During the O & M period, contractor shall give training to the members of WUA about O
& M of PDN work and its efficient use and protection of the system from any damages.
record to WUA. Along with this, the detailed Geotagged map of laid pipeline shall also be
handed over to WUA.
• In association of the members of WUA, the Engineer In-charge shall confirm the release
of designed discharge through every outlet before handing over. In case of any short fall
or defect, it should be made good from the contractor at his own cost.
769
SPECIFICATION FOR GLASS FIBER REINFORCED PLASTIC PIPES (GRP)
12.36 Providing and supplying Glass fibre reinforced plastic (GRP) pipes (Item
No. LIPDN 45)

Providing and supplying Glass fibre reinforced plastic (GRP) pipes confirming to IS 14402
with double bell REKA GRP coupling EPDM rubber gaskets for sealing of following
pressure diameter and stiffness class including cost of all material and labour required,
insurance, transportation to store, unloading and stacking excluding GST levied by GOI &
GOM in all respect etc. complete.

This specification covers requirements for Providing and supplying of machine made pipes
with glass fibre reinforced thermosetting resin with or without aggregate filler having nominal
diameter from 200 mm to 3 000 mm for use at pressure up to 1 500 kPa for conveyance of
water.

 Introduction
Glass fibre reinforced Plastic (GRP) pipe is a machine made tubular pipe containing
glass fibre reinforcements embedded in or surrounded by cured thermosetting resin. The
composite structure may contain silicious aggregates, fillers, thixotropic agents.
Thermoplastic or thermosetting liner and/ or surface layer may be provided for pipe.
As with many other composite materials, the two materials supplement each other to
form a stronger compound. Plastic resins are strong in compressive loading; the glass fibres
are very strong in tension. By combining the two materials, GRP becomes a material
that resists both compressive and tensile forces very well.
The Contractor shall provide on-site training on GRP pipe laying, jointing, testing and
maintenance etc., to the personnel authorized by Engineer-in-charge. The contractor should
provide technical Manual on GRP pipes including precautions to be taken during operation of
the pipeline.
770
The manufacturing, testing, supplying, laying, jointing and testing at work sites of
GRP pipes shall comply with all currently applicable statutes, regulations, standards and
referred. In all cases the latest revision of the Codes shall be referred to. If requirements of
this Specification conflict with the requirements of the standards / Codes, this Specification
shall govern. Others Codes not specifically mentioned here but pertaining to the use of GRP
Pipes form part of these Specifications.
IS 12709 Glass Fiber Reinforced Plastics (GRP) pipes, joints and fittings for
use for Potable water supply
IS 13916 Code of practice for Installation of Glass Fiber Reinforced
Plastic(GRP)piping system
IS 14402 GRP pipes joints and fittings for use sewerage, industrial
waste and water (Other than Potable)
IS 11273 Woven roving fabrics of 'E' glass fiber
IS 11320 Glass fiber rovings for the reinforcement of
polyester and epoxide resin systems
IS 11551 Glass fiber chopped strand mat for the reinforcement of polyester
resin system.
IS 5382 Rubber sealing rings for gas mains, water main sand sewers
 Raw Materials
Raw material use to manufacture the GRP Pipes is Resins, Glass Fiber Reinforcement,
Aggregates, Filler and Additives.
 Resins- Appropriate type of unsaturated polyester resins system confirming to IS 6746
shall be used. The resin and additives used shall be such that they contain no
ingredients, that is, in an amount that has been demonstrated to migrate into water in
quantities that are considered to be toxic.
 Glass Fiber Reinforcement- Glass fiber reinforcement shall be commercial grade E
type (i.e. which does not contain more than 1% by mass of alkali) and shall conform to
IS 11273, IS 11320or IS 11551as appropriate.
 Aggregates- Silicious sand of size range between 0.05mm and 0.8mm may be
incorporated in composite structure.
 Filler- Inert Fillers (with particle size below 0.05mm) may be incorporated either on
their own or with aggregates.
 Additives- Additives may be incorporated for modifying the properties of the resin.
The General requirement relating to the manufacture of GRP pipes shall be conforming to
IS-12709and IS 11273.
There are 3 basic methods of GRP Pipe manufacturing.
a. The Filament Winding Method
b. The Hand Lay-up Method
c. The Centrifugally Cast Method
771
In this, there are 2 different methods as given below.
i.The Discontinuous (also known as the Dual Helical Filament Winding Method)
The resin-impregnated continuous fiber rovings are wound at a controlled helix angle
in each selected direction on a removable mandrel.
ii.The Continuous filament winding method. Using the continuous advancing mandrel
process a very compressed laminate is created that maximizes the contribution from
the three basic raw materials glass-fiber, resin and sand.
It is a 100% manual operation and used for manufacturing GRP Pipes of very small
diameters. Hand lay-up typically achieves the best overall strength in irregular shapes
and has a higher overall corrosion resistance than filament wound pipe. The difference
between the above two techniques is the orientation and layering of the glass fibers.
Hand lay-up method utilizes woven glass rovings as opposed to continuous glass
rovings.
c. The Centrifugally Cast method
Multi-End rovings going through a chopper and resin are sprayed into a rotating,
cylindrical, metal mould. The resin impregnates the reinforcement under the effect of
the centrifugal force and forms, after polymerization, a cylindrical structure.
Centrifugal casting is particularly well suited for producing structures with large
diameters. The pipe wall is built up from the outside inwards in a rotating mould.
Once all the materials have been fed into the mould, the speed of rotation is increased.
High centrifugal forces up to 75 g (g-force) press them against the mould wall. Any
trapped gas is fully vented and the raw materials are condensed to a maximum,
creating a high quality, very solid and void free pipe wall. In the final step of
production, the pipe is heated to cure (the resin hardens).
 Classification Of Pipes:-
The pipes are classified on the basis of pressure rating & stiffness class.
 Pressure Class (PN) :Pressure classes of pipes are 5 namely PN3, PN6, PN9, PN12 and
PN15 correspond to the working pressure rating of 300, 600, 900, 1200 and 1500 KPa
respectively.
 Stiffness Class (SN) : Four Stiffress classes of pipes are 4 namely A,B,C, and D
correspond to minimum pipe Stiffness valve of 62,124, 248 and 496 kPa respectively at 5
% deflection.
All pipes of same pressure class, stiffness Class and produced under relatively uniform
composition and condition of manufacture shall constitute a lot One pipe
selected at random from a lot shall be checked for conformance to the dimensions,
workmanship, pipe stiffness, Hydraulic test, longitudinal strength test, hoop tensile
strength test and additional tests to establish potability of water as mentioned in following
para.
The lot shall be declared as conforming to the requirements of the specification, if the
sample pipe meets the requirements of all the tests, otherwise not.

Pipe selected as per sampling criteria mentioned in earlier para 5.0 are subject to
772
1. Dimension: Inside diameter, Outside diameter, Length of Pipe, Out of Squareness
of Pipe, Wall thickness.
2. Workmanship
3. Pipe Stiffness
4. Hydraulic test
5. Longitudinal Strength Test.
6. Hoop Tensile Strength Test.
7. Tests to establish potability of water
 Dimensions
a. Inside Diameter
Inside diameters of pipes shall be within the range given in following Table No.1 and
shall meet the tolerance as specified in this table
Table 1 Specified Inside Diameters and Tolerances All dimensions in millimeters.

Nominal Diameter, DN Inside Diameter Range, ID Tolerances on Declared ID
Min Max
200 196 204 +/-1.5
250 246 255 +/-1.5
300 296 306 +/-1.8
350 346 356 +/-2.0
400 396 408 +/-2.4
450 446 459 +/-2.7
500 496 510 +/-3.0
600 596 612 +/-3.6
700 695 714
800 795 816 +/-4.2
900 895 918
1000 995 1020
1100 1095 1120
1200 1195 1220
1300 1295 1320
1400 1395 1420
1500 1495 1520
+/-5.0
1600 1595 1620
1800 1795 1820
2000 1995 2020
773
Nominal Diameter, DN Inside Diameter Range, ID Tolerances on Declared ID
Min Max
2200 2195 2220
2400 2395 2420
2600 2595 2620 +/-6.0
2800 2795 2820
3000 2995 3020
b. Outside Diameter
The Outside diameter of pipes shall be as given in following Table No.2, subject to
tolerance as specified in this table.
Table No.2 Specified outside diameters and Tolerances

Sr. Nominal Outside diameter Outside Diameter Tolerance

No. (DN) mm (OD)
1 200 208 + 2.0
2 250 259 + 2.1
3 300 310 + 2.3
4 350 361 + 2.4
5 400 412 + 2.5
6 450 463 + 2.7
7 500 514 + 2.8
8 600 614 + 3.0
9 700 718 + 3.3
10 800 820 + 3.5
11 900 922 + 3.8
12 1000 1024 + 4.0
13 1100 1126 + 4.3
14 1200 1228 + 4.5
15 1300 1330 + 5.0
16 1400 1432 + 5.0
17 1500 1534 + 5.0
18 1600 1636 + 5.5
19 1800 1840 + 6.0
20 2000 2044 + 6.5
21 2200 2248 +7.0
22 2400 2452 +7.5
23 2600 2656 +8.0
24 2800 2860 +8.5
25 3000 3064 +9.0
774
c. Lengths- Pipes shall be in effective lengths of 6m, 9m and 12m. The tolerance on
lengths shall be within ± 25mm.
d. Out of Squareness of Pipe: All points around each end of a pipe unit shall fall within
±6.5mm or ± 0.5 percent of the nominal diameter of the pipe whichever is greater, to a
plane perpendicular to the longitudinal axis of the pipe when measured in accordance
with of IS 12709
e. Wall thickness- The minimum wall thickness at any point shall not be less than the
wall thickness specified in the manufacturer's data sheets. The manufacturer shall
ensure that the wall thickness specified in his data sheet shall be such as to satisfy the
inside or outside diameters as per Table No.1 or Table No.2 above.
 Workmanship
Workmanship shall be in accordance with good practice as listed in following Table No. 3
and shall meet the acceptance criteria specified.
Table no.3 : Allowable Defects (Reproduced from IS 12709)
Name Definition Visual Acceptance Levels
Chip A small piece broken off an edge or surface Maximum dimension of

break 6.5 mm
Crack An actual separation of the laminate, visible None
on opposite surfaces and extending through
the thickness
Crack, surface Crack existing only on the surface of a Maximum length, 6.5 mm
laminate
Crazing Fine cracks at or under the surface of a Maximum dimension of
laminate crazing, 2.5 mm
Delamination Separation of the layers of material at the Maximum dimension, 6.5 ,,
edge edge of a laminate
Delamination Separation of the layers of material in a None
internal laminate
Dry-spot Area of incomplete surface film where the Maximum diameter, 14 mm
reinforcement has not been wetted with
resin
Foreign Metallic particles included in a laminate Maximum dimension,
inclusion(metallic) which are foreign to its composition 1.5mm
Foreign inclusion Non-metallic particles of substance included Maximum dimension, 1.5
(non-metallic) in a laminate which seem foreign to its mm
composition
Fracture Rupture of laminate surface without Maximum dimension, 29
complete penetration mm
Air bubble (void) Air entrapment within and between the plies Maximum diameter, 3.0
of reinforcement, usually spherical in shape mm
Blister Rounded elevation of the surface of a Maximum diameter, 6.5
laminate, with boundaries that may be more mm; height from surface
or less sharply defined, somewhat not to be outside drawing
resembling in shape a blister on the human tolerance
skin
775
 Pipe Stiffness
Each length of pipe shall have sufficient strength to exhibit the minimum pipe
stiffness (F/ ∆y) specified in the following Table 4when tested in accordance with of
IS 12709
Table No.4 Pipe Stiffness at 5 percent Deflection
Pipes shall be capable of being deflected to level 'X' with no visible damage in the test
specimen evidenced by surface cracks and to level 'Y' with no indication of structural
damage as evidenced by inter laminar separation, separation of the liner or surface layer (if
incorporated) from structural wall, tensile failure of the glass fiber reinforcement and
fracture or buckling of the pipe wall, when tested in accordance with IS 12079
Deflection Ring deflection without Damage or Structural Failure, in Percent

Level for pipe of Stiffness Class
A B C D
Level, X 18 15 12 9
Level, Y 30 25 20 15
 Hydraulic test :-
Each length of pipe of nominal diameter up to 1400 mm shall withstand without leakage
or cracking the internal hydrostatic test pressures as specified in following Table 5 for the
applicable class when tested in accordance with IS 12709. For pipes of nominal diameter
above 1400 mm, the frequency of hydrostatic leak tests shall be as agreed between the
Table 5 Hydrostatic Test Pressures
Pressure Class Hydrostatic Test Pressure

PN kPa
3 600
6 1 200
9 1 600
12 2 400
15 3 000
776
 LONGITUDINAL STRENGTH TEST
For size up to DN 600 the pipe shall withstand, without failure, the beam loads specified
in following Table 6, when tested in accordance with IS 12709. For pipes sizes larger than
DN 600 and alternatively for smaller sizes adequate beam strength shall be demonstrated
by tensile tests conducted in accordance with IS 12709 for pipe wall specimens oriented in
the longitudinal direction. The minimum tensile strength specified in Table 6 shall be
complied with
Table 6 Beam Strength Test Loads and Longitudinal Tensile Strength of Pipe Wall
Nominal Beam Minimum Longitudinal Tensile Strength in kN/m of

Diameter Load P Circumference for Pressure Class of
DN kN PN 3 PN 6 PN 9 PN 12 PN 15
200 3.6 102 102 102 102 102
250 5.3 102 102 102 102 110
300 7.1 102 102 102 112 136
350 9.8 102 102 115 131 154
400 13.3 102 102 130 149 177
450 17.8 102 102 138 159 185
500 19.6 102 102 154 176 205
600 28.5 102 123 184 211 246
700 - 102 140 215 246 280
800 - 102 154 231 265 304
900 - 105 174 260 298 341
1 000 - 122 193 290 331 379
1 100 - 127 212 318 363 417
1 200 - 140 212 318 363 431
1300 - 152 226 345 393 498
1 400 - 164 247 371 423 504
1500 - 175 265 397 454 540
1 600 - 185 283 423 484 574
1 800 - 206 318 476 545 646
2 000 - 231 329 492 563 678
2 200 - 254 361 541 619 745
2 400 - 280 394 591 676 813
2 600 - 301 427 640 732 880
2 800 - 326 459 690 789 949
3 000 - 347 492 739 844 1 016
 Hoop tensile strength test :-

All pipes manufactured as per this specification shall meet or exceed the hoop tensile
strength shown for each size and class in following table No.7, when tested in
accordance with IS 12709.
777
Table 7 Minimum Hoop Tensils Strength of Pipe Wall
Nominal Minimum Hoop Tensile Strength in kN/m Width of
Diameter Circumference for Pressure Class
(mm)
PN 3 PN 6 PN 9 PN 12 PN 15
200 122 244 366 488 610
250 152 304 456 608 760
300 182 364 546 728 910
350 213 426 639 852 1 065
450 243 486 729 972 1 215
500 304 608 912 1 216 1 520
600 365 730 1 095 1 460 1 825
700 425 850 1 275 1 700 2 125
800 486 972 1 458 1 944 2 430
900 547 1 094 1 641 2 188 2 735
1 000 608 1 216 1 824 2 432 3 040
1 100 668 1 336 2 004 2 672 3 340
1200 729 1458 2187 2916 3645
1300 790 1580 2369 3159 3949
1 400 851 1 702 2 553 3 404 4 255
1500 911 1823 2734 3645 4556
1 600 972 1 944 2 916 3 888 4 860
1 800 1 094 2 188 3 282 4 376 5 470
2 000 1 215 2 430 3 645 4 860 6 075
2 200 1 337 2 674 4 011 5 348 6 685
2 400 1 458 2 916 4 374 5 832 7 290
2 600 1 580 3 160 4 740 6 320 7 900
2 800 1 701 3 402 5 103 6 804 8 505
3 000 1 823 3 646 5 469 7 292 9 115
TESTS TO ESTABLISH POTABILITY OF WATER

Pipe specimen shall be subjected to tests specified below as per IS 12709 in order to establish
the suitability of these pipes for use in carrying potable water.
i) Smell of the extract,
ii) Clarity of the colour of the extract,
iii) Acidity and alkality,
iv) Global migration,
v) UV absorbing material,
vi) Heavy metals,
vii) Unreoctd monomers (styrens)
viii) Biological tests
2. Grade of raw material
3. Pressure rating.
4. Nominal diameter
778
5.Lot/batch No. of manufacturer.
6.BIS certification mark.
7.Third Party Certification mark for each lot
8.Name of Department/Project for pipe which pipes are manufactured.
9.Any other important matter that the manufacturer or purchaser deems fit to be
inscribed.
Following precaution shall be taken during transportation of pipes.
 The truck used for transportation of the GRP pipes shall be exclusively used for GRP
pipes only with no other material loaded – especially no metallic, glass and wooden
items. The truck shall not have sharp edges that can damage the Pipe.
suitably and neatly on contractors yard along the alignment/road side/elsewhere near by
the work site or as directed by the Engineer In-Charge.
• All pipe sections and fittings shall be supported on timber saddles spaced at 4 m centres
with a maximum overhang of ‘2 m. Stock height should not generally exceed 2 m.
Pipes shall be strapped to the vehicle over the support points using non-metallic pliable
straps or ropes only.
• All the pipes and fittings shall be lifted with pliable straps, slings or ropes. These may
be canvas or polyester belts with a minimum width of 10 cms or nylon ropes with a
minimum diameter of 30 mm. Steel cables or ropes shall not be used for lifting and
transportation of pipe. Ropes shall not pass through the section of the pipe end to end.
• Straight continuous lengths of pipe may be lifted at one point. However, owing to its
very smooth surface it is usually safer for the pipe to be lifted at two points.
• Pipes assemblies fabricated in multiple sections or special places shall be lifted with two
or more lifting points.
• Pipes shall not be dropped to avoid impact or bump. If any time during handling or
during installation, any damage, such as gouge, crack or fracture occurs, the pipe shall
be repaired if so permitted by the competent authority before installation.
• Stacking Of Pipes
Following precaution shall be taken so as to eliminate potential damage to pipes.
• Pipes and fittings with diameters of less than 1.0 m may be stored directly on sandy soil,
the ground should be flat and free from sharp, projection and stones/rocks bigger than
40 mm in diameter or of other potentially damaging debris.
• Pipes with diameters greater than 1.0 m may be stored on their delivery cradles at a
maximum distance of 6 m c/c.
• If the surface is not flat or is sloping, then all the pipes shall be checked to prevent rolling.
• All rubber rings, gaskets and other items shall be stored in a cool, dry and dark
place to avoid damage of any kind.
• Valves
at various location.
Air Valve :
779
timely; finally, during the pump failure or maintenance stages, the air valve will replenish
the gas into the pipe to break the vacuum. According to the orifice size, displacement and
work pressure, air valve is divided into high pressure trace exhaust valve, low pressure air
Scour Valve :
drain pipeline.
Control Valve :
D) Sliding Stem
 Globe valve
E) Rotary
 Butterfly valve
 Ball valve
F) Other
 Pinch valve
 Diaphragm valve
be conducted on random samples of pipes collected from site.
 Work of PDN shall be inspected, tested and certified by PMC / TPI / QC. Modalities
charge.
and Calibration Laboratories). Third party Inspection can be done form any one of
the following services or from any other mutually agreed agency.
2. R.I.T.E.S. (Rail India Technical Economics Services), Mumbai
3. S.G.S, Mumbai
5. VJTI, Mumbai
780
(e) All materials before being utilized in works shall be inspected and tested, by the
otherwise specified. Labours for collecting samples and transportation of the
samples to quality control authorities for test shall be provided free of cost by the
contractor. Also electricity, fuel, water curing tank and stores etc shall be provided
free of cost by the contractors.
(f) The materials shall be tested in QC laboratory or at any other place directed by the
the work, materials and finished item to the standard as determined by the laboratory
(g) Testing charges for testing of Cement, TMT bars, all types of pipes and specials
(h) The Contractor shall make suitable arrangements to see that one of his
 On award of contract, the Contractor will have to provide adequate quality assurance
Quality Assurance.
781
Two to Four
(As per work)
testing of material)
(One for each L.A.)
 Following minimum equipments shall be available in the field laboratory set up by the
contractor.

for Sand & Metal.


The other tests of mortar, concrete, sand, coarse aggregates etc. Shall be carried out
in field laboratory setup by the contractor in presence of quality control
representative at contractors cost. Contractor shall through this procedure assure the
quality of work.
 The materials, mixes and any other arrangements, including labours, shall be supplied
specification.
782
work.

 Pre delivery testing of pipes shall be carried out by the contractor in the presence of
representative of Engineer-In-charge /WRD/QC/TPI..
 Each pipe shall be indelibly marked in English language at either end of each pipe.
 The truck used for transportation of the GRP pipes shall be exclusively used for GRP
pipes only with no other material loaded – especially no metallic, glass and wooden
items. The truck shall not have sharp edges that can damage the Pipe.
 Pipes manufactured at factory are to be carried to the site of work directly or stacked
suitably and neatly on contractors yard along the alignment/road side/elsewhere near
by the work site or as directed by the Engineer In-Charge.
 All pipe sections shall be supported on timber saddles spaced at 4 m centres with a
maximum overhang of ‘2 m. Stock height should not generally exceed 2 m. Pipes
shall be strapped to the vehicle over the support points using non-metallic pliable
straps or ropes only.
 All the pipes shall be lifted with pliable straps, slings or ropes. These may be canvas
or polyester belts with a minimum width of 10 cms or nylon ropes with a minimum
diameter of 30 mm. Steel cables or ropes shall not be used for lifting and
transportation of pipe. Ropes shall not pass through the section of the pipe end to end.
 Straight continuous lengths of pipe may be lifted at one point. However, owing to its
very smooth surface it is usually safer for the pipe to be lifted at two points.
 Pipes assemblies fabricated in multiple sections or special places shall be lifted with
two or more lifting points.
 Pipes shall not be dropped to avoid impact or bump. If any time during handling or
during installation, any damage, such as gouge, crack or fracture occurs, the pipe
shall be repaired if so permitted by the competent authority before installation.
 Pipes and fittings with diameters of less than 1.0 m may be stored directly on sandy
soil, the ground should be flat and free from sharp, projection and stones/rocks bigger
than 40 mm in diameter or of other potentially damaging debris.
 Pipes with diameters greater than 1.0 m may be stored on their delivery cradles at a
maximum distance of 6 m c/c.
 If the surface is not flat or is sloping, then all the pipes shall be checked to prevent
rolling.
 All rubber rings, gaskets and other items shall be stored in a cool, dry and dark place
to avoid damage of any kind.
783
 After delivery of pipes to worksite, additional test, if desired by Engineer-in-charge,
shall be conducted on random samples of pipe collected from site.

Measurement
 The net length of pipes as laid or fixed shall be measured in running meters correct to

shall be as under:-
B. 80% of the payment will be released after supplying, lowering, laying, jointing and
respective WUAs.
----------***----------
784
12.37 Lowering, laying and jointing in proper grade and alignment Glass fibre
reinforced plastic (GRP) pipes (Item No. LIPDN 46)
Lowering, laying and jointing in proper grade and alignment Glass fibre reinforced plastic
(GRP) pipes with couplings & gasket including cost of conveyance from stores to site of
works, all labour involved, etc. complete (for all class of pipes).

testing at works and site of Glass fibre reinforced plastic (GRP) pipes used for water supply.

removed by the Contractor. The ownership of all the usable material, so removed from
clearing site and/or excavation shall rest with the Engineer In-charge. Useful material shall
be stacked as directed. The Contractor shall dispose off all un-useful materials as directed by
the Engineer In-charge.
 Demarcation
All materials such as pegs, bamboo’s and strings and templets for marking out slopes, and
labour required for line out should be provided by the Contractor at his own cost. The center
fixing reference stone at suitable distances on either side of the center line, beyond the canal
edges so that they are not disturbed during the construction period. The position of these
stones will be marked on the cross section.

(a) Benchmarks fixed by the Survey of India and temporary benchmarks established
by the Engineer In-charge in vicinity of PDN work will serve as control points for
these works. The Contractor shall establish sufficient number of reference
benchmarks for facilitating setting out of work and taking levels for the purpose of
measurements.
(b)Before starting any work, the Contractor shall erect reference benchmarks,
reference lines and check profiles at convenient locations approved by the Engineer
In-Charge. The benchmark concrete block shall be 200mm x200mm x600mm with
400mm embedded in the firm ground and 200 mm projecting above ground. The
785
word ‘BM’ showing value of R.L. in ‘m’ shall be conspicuously carved and painted
on the benchmark.
(c)The check profile shall be located 30m apart or closer as directed by the Engineer
In-Charge so as to ensure execution of all slopes, steps and elevations to the profile or
profiles indicated in the approved drawings. All important levels and all control
points with respect to benchmarks and reference lines shall be fixed and correlated by
the Contractor. The Contractor is fully responsible for maintaining all setting out
work & Benchmark established by Engineer-In-charge.
(d)All materials, labour and equipments (theodolites, levels, distometre, etc.) for
setting out works including construction of benchmarks in concrete, reference lines,
check profiles and surveys as may be required at the various stages of construction
shall be supplied by the Contractor at his cost. For this following numbers of
minimum equipments shall be provided and maintained in good working condition
by the Contractor.
3. Levels 2Nos.
4. Staves 4Nos.
In-Charge.
drawing or as directed by Engineer In -charge. Contractor must assume all responsibility
for deductions and conclusion made by him as to the nature of the materials to be
excavated and the difficulties of making and maintaining the required excavation. The
trench width at bottom shall be 300 mm more than 1.5 times outside pipe diameter. In
any case trench width shall not be less than 500 mm.
used in backfilling. If such usable material is in excess of the requirement of backfilling,
the same shall be deposited in the spoils as and where directed by the Engineer In-
charge. Un-useful material from excavation shall be deposited in spoils as and where
directed by Engineer-In-charge.
 Surface or sub-soil water met with during trench excavation (PDN) and structure
786
material excavated under water level condition which requires intermediate stacking for
drying shall have to be rehandled. No extra payment for efforts for drying out of soil, re-
handling of dry soil, etc. shall be given. No payment for extra efforts for excavation
under this condition shall be made.
 Over excavation performed by the Contractor for any purpose or reason, except for
additional excavation as may be directed by the Engineer-In-charge, shall be rectified at
the cost of the Contractor. Filling and compaction for such over excavation using the
material as directed by the Engineer In- Charge shall also be at the cost of the
Contractor.
structure shall be over excavated to the extent as directed by the Engineer In Charge and
such over excavated section shall be filled with suitable murum type soil to be placed in
uniformly compacted layers as directed by the Engineer In Charge. The over excavation
made in such strata, filling by suitable soil, and watering and compacting such soil will
be paid separately under relevant items. Above provision for over excavating and filling
with suitable murum type or good soil available material shall be applicable in case such
treatment is found essential.
 Laying of Pipes
While laying of pipes all precautions as mentioned in IS 13916 shall be taken
 Laying should take place only after the trench and the surface supporting the
pipes have been prepared according to the specification.
 For a coupling type of joint, two rubber ring gaskets are first fixed into the groove
inside the coupling and then the coupling is to be fixed at the coupling area of the pipe
and pipe is to be lowered in the trench.
 Before placing a pipe in the trench, it is necessary to clean any remains of earth, sand
or mud from the inside of the socket and from the opposite end bearing the rubber ring
gasket/packing. When cleaning has taken place, run a hand around inside the socket to
ensure that there are no residues of hardened resin which can be removed readily with
a chisel. It is also necessary to check that the groove has an even depth and has not
been damaged for instance, during carriage of handling.
 Place the pipe in the trench, taking care to dig a small hollow at each end so that the
groove and the socket are well separated from the sand and gravels in the bottom of
the trench.
 Anchor the first pipe section laid according to the method described and leave its ends
free along a space enough for insertion of the next section and for checking. Place the
next pipe section in the trench and leave enough space for the operator to be free to
move and to work between the two pipe sections so as to carry out the cleaning and
checking operations.
787
 Clean the coupling area of the joint once more with a cloth and also clean the flared
portion of the lead-in using suitable lubricant.
 Clean the groove again, take the rubber ring gasket and lubricate it by running it
between the hands and checking at the same time, it being in good condition. It should
be ensured that every portion of the ring or inside of the socket must not lacks
lubricant as it will impair good insertion of the pipe.
 For socket and spigot type of joint, pass the rubber ring under the pipe until it settles
into the groove, then pull it forcibly upwards and follow the ring with the hands so that
three quarters of it is positioned in the groove, then lift the ring above the upper
generating line of the pipe forcibly and then release it so that it falls into the groove
thus being freed of any twists.
 Run the hands around the pipe to check that the whole of the packing is in its seating
and, in the case of large diameter pipes, smear lubricant again above the inserted
rubber ring gasket/packing.
 Align and bring together the two pipe sections until rubber ring touches the flared
portion of the lead-in. When this has taken place, examine the position of the ring and
above all, ensure that there are no sand or other foreign bodies present.
 Fit the socket onto the spigot very slowly dwelling half way along the coupling area,
and check the position of the packing visually.
 Proceed with the joint until the socket is halted by the abutment ledge. The next pipe
section should not be fitted until the previous pipe section has been anchored with an
overlay of sand.
 Check the rubber ring gasket/packing after the joint has been coupled. This check must
always be carried out and is performed with a blade of steel or of another metal having
a thickness of 0.4/0.5 mm, a width of 15 mm and any length greater than 200 mm, the
blade being inserted into the annular space between the socket and the spigot. This
check should be conducted along all the circumference where the packing is
compressed so as to ensure that the rubber ring has a homogeneous depth and is
therefore correctly positioned in its seating. If the ring is found to be seated differently
at one point than other points or if there is any doubt, disconnect the joint, check the
rubber ring and replace it if it shows any permanent signs of faulty seating, check once
more the coupling area of the joint, the flared, lead-in of the socket and the groove on
the spigot. When re-inserting the pipe section, take extra care to align the pipes
perfectly. When uncoupling pipe sections, never use chains or steel cables in direct
contact with the pipes.
 Check once again the position of the ring with the blade.
 RCC thrust blocks should be provided at bends and at places of reductions in cross
section to take care of thrust.
788
 The pipe should be uniformly and continuously supported throughout its whole length
with firm stable bedding material. The bedding material should be placed so as to give
complete contact between the bottom of the trench and pipe. The bedding material
should be watered and compacted.
Jointing Of Pipes
Jointing of pipe should be done as per procedure mentioned in IS 13916.
The pipe shall have a jointing system that shall provide for fluid tightness for the intended
service conditions. Selections of different pipe jointing system depend upon location, site
and working condition, pressure and flow of liquids. The commonly used joints are as
follows.
 Unrestrained Pipe Joint
These pipe joints are capable of withstanding internal pressure but not longitudinal
forces. These joints however can accommodate the linear variation of the pipe due to
temperature variation. These joints are of 3 types as mentioned below.
 Spigot and Socket Joint with Single Water Tight-Rubber Ring Gasket/Packing This
type of joint enables a pipeline to be laid speedily and is suitable for low (up to 3 PN)
pressures in buried lines.
 Spigot and Socket Joint with Double Watertight Rubber Ring Gasket/Packing This
joint is made with double rubber ring and is suitable for high pressure (3 PN and
above).
789
 Double Socket Coupling Joint with Watertight Rubber Ring Gasket/Packing This joint
is made with double socket type coupling and is suitable both for low and high
pressure.
The pipe to be connected shall be placed on the bed with the sufficient distance from
previously joined pipe to allow lowering of pipe with the coupling into position. Pull
the pipe with coupling on to the previously laid pipe by means of jack after clamping
the pipe. Care shall be taken in the alignment of the coupling with pipes.
 Restrained Pipe Joint

The restrained type pipe joint is capable of withstanding internal pressure and
longitudinal forces. For pipe line consisting of restrained joints only, expansion joints
shall be provided in consultation with the manufacturer of pipe fittings. These joints
are of 5 types as mentioned below.
 Spigot and Socket Joint with Gluing

This joint is suitable for underground applications under conditions of normal outside
loads and low pressures. It is easy to make and enables a high laying speed to be
reached. The glueing is to be done by polyester cement or any other adhesive suitable
for a hydraulic and mechanical seal.
 Spigot and Socket Joint with Glue and Overlay

This type of joint is suitable both for low and high pressure. Gluing the joint should be
done with suitable adhesive and overlay with the same material as used in pipe. The
minimum thickness of overlay shall be 1.5 times of the thickness of pipes.
790
 Butt Joint
It is used for running pipes and for the connection of straight runs to fittings
(reduction, elbows, flanges, etc). The minimum thickness of joint ‘t’ shall not be less
than the thickness of pipe. Width of overlay shall not be less than ten times the
thickness of the pipe on either side of the joint.
 Flanged Joint
The flange joint is used for connecting the valves, pumps or any other apparatus or
pipes of different materials. The flanged joint is made from the same material as the
pipe.
 Steel Collar on GRP Pipe for Flanged Connection
A steel loose flange is slipped on to a GRP pipe and then a hand layup collar is done.
The steel collar may now be connected to any flanged connection.
791
 Backfilling of Pipe Trenches
as prescribed in this paragraph or as directed by the
Engineer-in-Charge.
structure. The backfill close to the structure up to the rolled layer shall be compacted
in suitable uniform layers, using pneumatic / hand tampers as appropriate for dry
density at average bulk density (+/- 10%). The moisture content of the earth fill
placed against the rock or the structure shall be on higher/lower side of OMC by
about 2% or so, to allow it to be compacted. Profuse watering shall be done to
pervious materials (sand) before compaction as per instruction of the Engineer-in-
Charge. Compaction at junction of earthwork and backfill around the structure shall
be carried out with special care.
792
farmers.
 The marking shall be constructed in prefabricated concrete block of size
(15x15x45)CM embedded in concrete block of size (30x30x30)CM. The base of
this block shall be buried in ground projecting only 15cm above the ground and the
base concrete block.
 These blocks shall be able to locate the pipeline as and where it is laid all over the
 The contractor shall show all this blocks jointly to the Engineer-in-charge or his
 Contractor shall maintain these blocks in proper order during operation &
maintenance period of the contract. Any damage done to these blocks for the reasons
whatsoever shall be made good at the cost of contractor.
 The contractor shall submit the location of such blocks with specific identification
 The map of marking of the block shall be handed over to WUA while handing over
the command area.
 The Geo-tagging map showing Latitude and Longitude value of each apex of laid
 The contract shall fix information boards of 1.2 m x 0.9 m size at various location as
charge.
3. S.G.S, Mumbai
5. VJTI, Mumbai
793

Quality Assurance.

Two to Four
(As per work)
(One for each L.A.)
794
 Following minimum equipments shall be available in the field laboratory set up by
the contractor.

for Sand & Metal.


quality of work.
specification.
work.

795
Engineer In-charge.
soil is encountered and over which PDN can not be directly laid, the PDN trench and
over-excavation made in such strata, filling by suitable soil, and watering and
for over-excavating and filling with suitable murum type or good soil available
 While laying of pipes all precautions as mentioned in IS 13916 shall be taken.
drawings.
 Laying should take place only after the trench and the surface supporting the pipes
have been prepared according to the specification.
 For a coupling type of joint, two rubber ring gaskets are first fixed into the groove
inside the coupling and then the coupling is to be fixed at the coupling area of the pipe
and pipe is to be lowered in the trench.
 Before placing a pipe in the trench, it is necessary to clean any remains of earth, sand
or mud from the inside of the socket and from the opposite end bearing the rubber ring
gasket/packing. When cleaning has taken place, run a hand around inside the socket to
ensure that there are no residues of hardened resin which can be removed readily with
a chisel. It is also necessary to check that the groove has an even depth and has not
been damaged for instance, during carriage of handling.
 Place the pipe in the trench, taking care to dig a small hollow at each end so that the
groove and the socket are well separated from the sand and gravels in the bottom of
the trench.
796
 Anchor the first pipe section laid according to the method described and leave its ends
free along a space enough for insertion of the next section and for checking. Place the
next pipe section in the trench and leave enough space for the operator to be free to
move and to work between the two pipe sections so as to carry out the cleaning and
checking operations.
 Clean the coupling area of the joint once more with a cloth and also clean the flared
portion of the lead-in using suitable lubricant.
 Clean the groove again, take the rubber ring gasket and lubricate it by running it
between the hands and checking at the same time, it being in good condition. It should
be ensured that every portion of the ring or inside of the socket must not lacks
lubricant as it will impair good insertion of the pipe.
 For socket and spigot type of joint, pass the rubber ring under the pipe until it settles
into the groove, then pull it forcibly upwards and follow the ring with the hands so that
three quarters of it is positioned in the groove, then lift the ring above the upper
generating line of the pipe forcibly and then release it so that it falls into the groove
thus being freed of any twists.
 Run the hands around the pipe to check that the whole of the packing is in its seating
and, in the case of large diameter pipes, smear lubricant again above the inserted
rubber ring gasket/packing.
 Align and bring together the two pipe sections until rubber ring touches the flared
portion of the lead-in. When this has taken place, examine the position of the ring and
above all, ensure that there are no sand or other foreign bodies present.
 Fit the socket onto the spigot very slowly dwelling half way along the coupling area,
and check the position of the packing visually.
 Proceed with the joint until the socket is halted by the abutment ledge. The next pipe
section should not be fitted until the previous pipe section has been anchored with an
overlay of sand.
 Check the rubber ring gasket/packing after the joint has been coupled. This check must
always be carried out and is performed with a blade of steel or of another metal having
a thickness of 0.4/0.5 mm, a width of 15 mm and any length greater than 200 mm, the
blade being inserted into the annular space between the socket and the spigot. This
check should be conducted along all the circumference where the packing is
compressed so as to ensure that the rubber ring has a homogeneous depth and is
therefore correctly positioned in its seating. If the ring is found to be seated differently
at one point than other points or if there is any doubt, disconnect the joint, check the
rubber ring and replace it if it shows any permanent signs of faulty seating, check once
more the coupling area of the joint, the flared, lead-in of the socket and the groove on
the spigot. When re-inserting the pipe section, take extra care to align the pipes
perfectly. When uncoupling pipe sections, never use chains or steel cables in direct
contact with the pipes.
 Check once again the position of the ring with the blade.
 RCC thrust blocks should be provided at bends and at places of reductions in cross
section to take care of thrust.
 The pipe should be uniformly and continuously supported throughout its whole length
with firm stable bedding material. The bedding material should be placed so as to give
complete contact between the bottom of the trench and pipe. The bedding material
should be watered and compacted.
797
 Jointing of pipe should be done as per procedure mentioned in IS 13916.
 The pipe shall have a jointing system that shall provide for fluid tightness for the
intended service conditions. Selections of different pipe jointing system depend upon
location, site and working condition, pressure and flow of liquids
of the farmers.

Measurement
The net length of lowering of pipes as laid or fixed shall be measured in running meters
correct to a cm. Specials shall be excluded and measured in running meters or numbers as

shall be as under:-
798
respective WUAs.
----------***----------
799
12.38 Providing and supplying ISI mark Glass fibre reinforced plastic pipes
(GRP)fitting/specials (Item No. LIPDN 47)
Providing and supplying ISI mark Glass fibre reinforced plastic pipes (GRP) fitting/specials
including loading, unloading, transportation up to departmental store, stacking excluding GST
levied by GOI & GOM in all respect etc. Complete.
This specification covers the requirements for providing and supplying ISI mark Glass fibre
reinforced plastic pipes (GRP) fitting/specials including loading, unloading, transportation up
to departmental store, stacking excluding GST levied by GOI & GOM in all respect etc.
complete.

 Introduction
Glass fibre reinforced Plastic (GRP) pipe is a machine made tubular pipe containing glass
fibre reinforcements embedded in or surrounded by cured thermosetting resin. The
composite structure may contain silicious aggregates, fillers, thixotropic agents.
Thermoplastic or thermosetting liner and/ or surface layer may be provided for pipe.
As with many other composite materials, the two materials supplement each other to form a
stronger compound. Plastic resins are strong in compressive loading; the glass fibres are
very strong in tension. By combining the two materials, GRP becomes a material
that resists both compressive and tensile forces very well.
The Contractor shall provide on-site training on GRP pipe laying, jointing, testing and
maintenance etc., to the personnel authorized by Engineer-in-charge. The contractor should
provide technical Manual on GRP pipes including precautions to be taken during operation of
the pipeline.
The manufacturing, testing, supplying, laying, jointing and testing at work sites of GRP pipes
conflict with the requirements of the standards / Codes, this Specification shall govern. Others
800
Codes not specifically mentioned here but pertaining to the use of GRP Pipes form part of
IS 12709 Glass Fiber Reinforced Plastics (GRP) pipes, joints and fittings for
use for Potable water supply
IS 13916 Code of practice for Installation of Glass Fiber Reinforced Plastic
(GRP)piping system
IS 14402 GRP pipes joints and fittings for use sewerage, industrial
waste and water (Other than Potable)
IS 11273 Woven roving fabrics of 'E' glass fiber
IS 11320 Glass fiber rovings for the reinforcement of
polyester and epoxide resin systems
IS 11551 Glass fiber chopped strand mat for the reinforcement of polyester
resin system.
IS 5382 Rubber sealing rings for gas mains, water main sand sewers
 Raw Materials
Raw material use to manufacture the GRP Pipes is Resins, Glass Fiber Reinforcement,
Aggregates, Filler and Additives.
 Resins- Appropriate type of unsaturated polyester resins system confirming to IS 6746
shall be used. The resin and additives used shall be such that they contain no ingredients,
that is, in an amount that has been demonstrated to migrate into water in quantities that are
considered to be toxic.
 Glass Fiber Reinforcement- Glass fiber reinforcement shall be commercial grade E type
(i.e. which does not contain more than 1% by mass of alkali) and shall conform to IS
11273, IS 11320or IS 11551as appropriate.
 Aggregates- Silicious sand of size range between 0.05mm and 0.8mm may be
incorporated in composite structure.
 Filler- Inert Fillers (with particle size below 0.05mm) may be incorporated either on their
own or with aggregates.
 Additives- Additives may be incorporated for modifying the properties of the resin.
The General requirement relating to the manufacture of GRP pipes shall be conforming to
IS-12709and IS 11273 .
There are 3 basic methods of GRP Pipe manufacturing.
c. The Centrifugally Cast Method
A. The Filament Winding Method
In this, there are 2 different methods as given below.
i. The Discontinuous (also known as the Dual Helical Filament Winding
Method) The resin-impregnated continuous fiber rovings are wound at a
controlled helix angle in each selected direction on a removable mandrel.
ii. The Continuous filament winding method
Using the continuous advancing mandrel process a very compressed laminate
is created that maximizes the contribution from the three basic raw materials
glass-fiber, resin and sand.
B. The Hand Lay-up Method
801
It is a 100% manual operation and used for manufacturing GRP Pipes of very small
diameters. Hand lay-up typically achieves the best overall strength in irregular shapes
and has a higher overall corrosion resistance than filament wound pipe. The difference
between the above two techniques is the orientation and layering of the glass fibers.
Hand lay-up method utilizes woven glass rovings as opposed to continuous glass
rovings.
c. The Centrifugally Cast method
Multi-End rovings going through a chopper and resin are sprayed into a rotating,
cylindrical, metal mould. The resin impregnates the reinforcement under the effect of
the centrifugal force and forms, after polymerization, a cylindrical structure.
Centrifugal casting is particularly well suited for producing structures with large
diameters. The pipe wall is built up from the outside inwards in a rotating mould.
Once all the materials have been fed into the mould, the speed of rotation is increased.
High centrifugal forces up to 75 g (g-force) press them against the mould wall. Any
trapped gas is fully vented and the raw materials are condensed to a maximum,
creating a high quality, very solid and void free pipe wall. In the final step of
production, the pipe is heated to cure (the resin hardens).
 Classification Of Pipes:-
The pipes are classified on the basis of pressure rating & stiffness class.
 Pressure Class (PN): Pressure classes of pipes are 5 namely PN3, PN6, PN9, PN12 and
PN15 correspond to the working pressure rating of 300, 600, 900, 1200 and 1500 KPa
respectively.
 Stiffness Class (SN): Four Stiffress classes of pipes are 4 namely A,B,C, and D
correspond to minimum pipe Stiffness valve of 62,124, 248 and 496 kPa respectively at 5
% deflection.
• Valves
Air Valve:
Scour Valve:
drain pipeline.
802
Control Valve:
A) Sliding Stem
 Globe valve
B) Rotary
 Butterfly valve
 Ball valve
C) Other
 Pinch valve
 Diaphragm valve

charge.
3. S.G.S, Mumbai
5. VJTI, Mumbai
803
assistants, labours and wellequipped laboratory for taking necessary field test required
as per specifications and as per instructions of Engineer in charge.
Quality Assurance.
Two to Four
(As per work)
(One for each L.A.)
 Following minimum equipments shall be available in the field laboratory set up by

the contractor.

for Sand & Metal.

Slump, Cube Moulds&CTM
804
quality of work.
specification.
work.
 All fittings/specials shall be fabricated or moulded at factory only. No

fabrication or moulding will be allowed at site, unless specifically permitted by
 For the desired quality of work. Whenever the testing of construction materials,
Engineer-in-Charge, the same shall be carried out at the laboratory, selected by
the Engineer-in-Charge at Contractor’s cost.

Measurement
The Specials of pipes as laid or fixed shall be measured in running meters correct to a cm
depending upon bend degree, no. of bend and no. of coupling, as specified by Engineer-
in-charge and paid for separately under the relevant item. The portion of the pipe
overlapped at the joints shall not be included in the length of pipe work. Excavation,
refilling, anchor blocks, thrust blocks wherever required shall be measured and paid for
separately under relevant items of work.
805
shall be as under:-
respective WUAs.
----------***----------
806
12.39 Hydraulic testing of Glass fiber reinforced plastic (GRP) pipes .
(Item No. LIPDN 48)
12.39.1Description of Item
Hydraulic testing of Glass fibre reinforced plastic (GRP) pipes to specified pressure
including cost of all materials and labour and water for testing for the length up to 1 km.,
using reciprocating type pumps which should be able to provide specified test pressure gauges
and other necessary equipments, labour, operation charges, etc. required for testing. The rate
under this item shall also include cost of retesting, if necessary.
This specification covers the requirements for hydraulic testing at works and site of
Glass fibre reinforced plastic (GRP) pipes to specified pressure including cost of all materials
and labour and water for testing for the length up to 1 km., using reciprocating type pumps
which should be able to provide specified test pressure gauges and other necessary
equipments, labour, operation charges, etc. required for testing. The rate under this item shall
also include cost of retesting, if necessary.
 Field Testing Of Pipeline System
 General
All pipelines should be tested before being brought into service. The test should be a
 Site Test Pressure
The test pressure shall be 1.5 times the rated pressure for a given class of pipes or
fittings. The test pressure shall be maintained for a period of 24 hours.
 Test Procedure
The following procedure is recommended for GRP pipe testing:
a) GRP pipelines shall be pressure tested at ambient temperature.
b) During the test period, make-up water is continuously added to maintain the
pressure.
 Leak Detection
Each full length of pipe section, fittings and joints shall be leak tight. If any leakage is
found during testing of pipeline, Contractor will have to attend immediately and
rectify at his cost. If Contractor fails to rectify the defect, the entire length of pipeline
between two adjacent outlets shall be rejected and not accepted. The payment shall not
be made for the rejected work. If any intermediate payment is made to the Contractor
for portion under rejection, the same shall be recovered from the outstanding dues of
the Contractor.

charge.
807
3. S.G.S, Mumbai
4. Visvesvaraya National Institute of Technology, Nagpur
5. VJTI, Mumbai

808
Quality Assurance.

Two to Four
(As per work)
(One for each L.A.)
 Following minimum equipments shall be available in the field laboratory set up by the
contractor.

for Sand & Metal.


quality of work.
809
specification.
work.
 The test should confirm to following conditions
component.
 Pipe systems should be hydraulically tested in lengths appropriate to the diameters and site
conditions. Pipelines longer than 800 m may require testing in sections. Preferably, the length
selected for test is between 300 m and 500 m.
 Testing should not take place until any concrete used for anchoring has fully cured (normally
72 h) and attained its required strength. Solvent cemented joints must be allowed to harden
for a minimum of 24 h before being subjected to test conditions.
 It is important to provide sufficient backfill over the main barrel of the pipe, to prevent
displacement and to maintain stable temperature conditions. Leave joints free for inspection.
 The test position should be located at the lowest point of the pipeline profile to encourage
expulsion of air as the pipe is being filled with water. Adequate air release mechanisms
should be located at all high points along the line.
 Before filling the pipeline, all line valves and air venting systems should be checked open. All
air must be removed from the system.
 Fill the system slowly. Water velocity must not exceed 0.6 m/s. Potable water pipelines
should be tested with potable water only. After charging, close all air valves and check proper
action of automatic valves.
 Allow the system to stabilize under a nominal pressure for a minimum of 2 hours. Apply
increase.
 The pressure should be increased till the specified pressure is reached at the lowest part of the
section. Maintain test pressure at this level, by additional pumping if necessary, for a period
of 1 hour.
 Close all valves and disconnect the pressurizing unit. No further water should be allowed to
enter the system for a further period of 1 hour.
 During the test period, carry out a visual examination of all joints and exposed connections.
 There should be no leakage in any part of the section.
 If there has been a decrease in pressure during this period other than due to leakage, the
original pressure is re-established by injecting a measured quantity of water into the section.
 The test is considered to be satisfactory if
810
 there is no decrease in pressure (a slight rise in pressure is also, possible due to changes in
ambient temperatures),
 the measured quantity of water required to reinstate the pressure to the original test pressure is
less than the ‘permissible maximum’ Q,
 Where, Q = 4.5 liters per 1.6 km per 25 mm of nominal bore per 30 m head of test pressure
per 24 hours.
 On completion of any test, the residual pressure should be released slowly and in a carefully
controlled manner.
 All defects revealed in the test should be rectified and the procedure repeated until a
 If any leakage is found during testing of pipeline, Contractor will have to attend the same
immediately and rectify at his cost . If Contractor fails to rectify the defect, the entire length
of pipeline between two adjacent outlets shall be rejected. If any intermediate payment is
made to the Contractor for portion under rejection, the same shall be recovered from the
outstanding dues of the Contractor.
 Third Party Inspection of PDN work shall be inspected, tested and certified by PMC/TPI/QC.
Modalities of PMC/TPI/QC Inspection shall be separately decided and given by Engineer-In-
charge.

Measurement
The Hydraulic Testing of pipes as laid or fixed shall be measured in Km correct to a m.
Engineer-in-charge and paid for separately under the relevant item. The portion of the
pipe overlapped at the joints shall not be included in the length of pipe work. Excavation,

shall be as under:-
respective WUAs.
----------***----------
811
Note:
 The contractor shall operate and maintain the complete pipe distribution network for
the period of 5 (five) years after commissioning. Out of this period, during last two years
the operation of the schemes shall be done by the contractor jointly along with WUA. On
completion of O & M period, the system shall be handed over to WUA
 During rotation period, once in every year, the Contractor shall perform
hydraulic test to the satisfaction of Engineer In-charge to verify the flow of designed
discharge, detect or confirm any leakage in the system and rectify at his own cost. The
testing shall preferably be conducted jointly with members of WUA/representative of
Engineer In-charge, technical representative of contractor and any other stake holder.
 On completion of every Irrigation season, the contractor shall flush the pipe line from
 During the O & M period, contractor shall give training to the members of WUA
about O & M of PDN work and its efficient use and protection of the system from any
damages.
 The contractor shall prepare a detail map of the permanent marking along the
alignment of pipe and submit the same to Engineer In-charge. The Engineer In-charge
shall verify and endorse the location of the marking and handover these signed maps as a
permanent record to WUA. Along with this, the detailed Geotagged map of laid pipeline
shall also be handed over to WUA.
 In association of the members of WUA, the Engineer In-charge shall confirm the release
812
SPECIFICATION FOR HIGH DENSITY POLYETHYLENE PIPE ( HDPE)
12.40 Providing and supplying in standard lengths Polyethelene Pipes (Item No.
LIPDN 49)

Providing and supplying in standard lengths Polyethelene Pipes, confirming to IS 4984 /
14151 / 12786 / 13488 with necessary jointing material like mechanical connector i.e. thread /
insert joint / quick release coupler joint / compression fitting joint or flanged joint excluding
coupler/specials, including transportation and freight charges, inspection charges, loading /
unloading charges, conveyance to the departmental stores & stacking the same in closed
shade duly protecting from sunrays & rains, excluding GST levied by GI & GOM in all
respect etc. complete.

This specification covers the requirements for providing and supplying high density
polyethylene pipes from 16 mm to 1000 mm nominal diameter of pressure rating from 0.25
MPa to 1.6 MPa in material grades of PE 63, PE 80, aud PE 100, for use for buried water
mains aud services and for water supply above ground.

 Introduction
HDPE pipe is a type of flexible plastic pipe used for fluid and gas transfer. HDPE material is
a polyethylene thermoplastic made from petroleum and its high level of impermeability and
strong molecular bond makes it suitable for high pressure pipelines. The toughness and
resistance to chemicals as well as the corrosion resistance and low weight have contributed to
its growing use in situations where cost effective and durable fluid and gas pipe systems are
required. HDPE pipe is made from food grade polyethylene virgin material as such they are
safe for the transfer of potable water.
The Contractor shall provide on-site training on HDPE pipe laying, jointing, testing and
provide technical Manual on HDPE pipes including precautions to be taken during operation
of the pipeline.
 Applicable IS -Codes, ISO Codes

The manufacturing, testing, supplying, laying, jointing and testing at work sites of HDPE
pipes shall comply with all currently applicable statutes, regulations, standards and Codes. In
Codes not specifically mentioned here but pertaining to the use of HDPE Pipes form part of
813
IS 4984 High Density Polyethylene Pipes for Water Supply
ISO 4427 HDPE pipes and fittings for water supply.
IS 8360 Specifications for fabricated HDPE fittings for potable water
supplies.(Part I to III)
IS 8008 Injection moulded/ machined HDPE fittings for potable water
supplies.(Part I to IX)
IS 7634 Part-II Laying & Jointing of Polyethylene (PE) Pipes
IS 7328 High density polyethylene materials for moulding and extrusion
IS 2530 Methods of test for polyethylene moulding materials and compounds.
IS 10141 Positive lists of constituents of polyethylene in contact with food stuffs,
pharmaceuticals and drinking water.
IS 9845 Method of analysis for the determination of specific and/or overall
migration of constituents of plastics material and articles intended to
come in to contact with food stuffs
IS 10146 Polyethylene for its safe use in contact with food stuff, Pharmaceuticals
and drinking water.
 Raw Materials
Raw material used to manufacture the HDPE Pipes is High Density Polyethylene of PE 63,
PE 80 and PE 100 grade.
 The material used for the manufacturer of pipes should not constitute toxicity hazard,
should not support microbial growth, should not give rise to unpleasant taste or odour,
cloudiness or discoloration of water. Pipe manufacturers shall obtain a certificate to this effect
from the manufacturers of raw material as per the satisfaction of the Engineer-in-Charge.
 High density Polyethylene(HDPE) used for the manufacture of pipes shall conform to
designation PEEWA-45-T-003 or PEEWA-45-T-006 or PEEWA-50-T-003 or PEEWA-50-T-
006 or PEEWA-57-T-003 or PEEWA-57-T-006ofIS7328. HDPE conforming to designation
PEEWA-45-T-012 or PEEWA-50-T-012 or PEEWA-57-T-012 of IS-7328 may also be used
with the exception that Melt Flow Rate(MFR) shall be between 0.20 to 1.10g/10min. In
addition the material shall also conform to clause 5.6.2 of IS7328.
 The Specified base Density shall be between 940.5 to 958.40 kg/m3 (both inclusive)
determined at 270C according to procedure prescribed in IS 7328. The value of density shall
not differ from the nominal/agreed value by more than 3 kg/m 3.
 The Melt Flow Rate(MFR) of the material shall be between 0.20 and 1.10gm/10 min.
(both inclusive) when tested at 190°C with nominal load of 5kgf as determined by method
prescribed in IS-2530. The MFR of the material shall also be within ±20 percent of the value
declared by the manufacturer.
 The resin shall be compounded with carbon black. The carbon black content in the
material shall be within 2.5±0.5% and the dispersion of carbon black shall be satisfactory
when tested as per procedure described in IS-2530.
 The percentage of anti-oxidant used shall not be more than 0.3 percent by mass of
finished resin. The anti-oxidant used shall be physiologically harmless and shall be selected
from the list given in IS 10141.
 The addition of not more than 10 % of the manufacturer's own rework material resulting
from the manufacture of pipes is permissible. No other reworked or recycled material shall be
used.
814
To make pipe lengths, HDPE material is heated and extruded through a die, which determines
the diameter of the pipeline. The wall thickness of the pipe is determined by a combination of
the size of the die, speed of the screw and the speed of the haul-off tractor. The General
manufacturing process of HDPE Pipe is as given the below.
• Polyethylene raw material is pulled from a silo, into the hopper dryer, which
removes any moisture from the pellets.
• Then it is pulled by a vacuum pump into blender, where it is heated by a barrel
heater. The PE material becomes molten at around 180 degrees Celsius, allowing it
to be fed through a mould/die, which shapes the molten material into a circular
shape.
• After coming through the die, the newly formed pipe quickly enters the 3-4 cooling
tanks, which submerge or spray water at the pipe exterior, each one reducing the
temperature of the pipe by 10-20 degrees.
• Because Polyethylene has a high specific heat capacity, the pipe must be cooled in
stages, to avoid deforming the shape, and by the time it reaches the 'haul-off
tractor', it is hard enough to be gently pulled by the 2-3 belts.
 Workmanship/Appearance
Pipes shall be free from all defect including indentations, delaminating,
bubbles, pinholes, cracks, pits, blisters, foreign inclusions that due to their nature,
degree of extent detrimentally affect the strength and serviceability of the pipe. The
pipe shall be as uniform as commercially practicable in colour opacity, density and
other physical properties as per relevant IS Code or equivalent International Code. The
inside surface of each pipe shall be free of scouring, cavities, bulges, dents, ridges and
other defects that result in a variation of inside diameter from that obtained on
adjacent unaffected portions of the surface. The pipe ends shall be cut clearly and
square to the axis of the pipe.
 Classification of Pipes:
a) Pipes shall be classified according to the grade of materials as given in following
Table No.1
Table No.1: Classification of Pipe material (Reproduced from IS 4984)
Sr. Material grade MRS ( Minimum required Maximum allowable
No. strength) of material in MPa hydrostatic design stress
(N/mm2)., @20 Degree Mpa. (N/mm2)
Celsius, 50 years
At 20 degree Celsius
1 2 3 4
i) PE 63 6.3 5.0
ii) PE 80 8.0 6.3
iii) PE 100 10.0 8.0
815
b) Pipe shall be classified by pressure rating (PN) corresponding to the maximum
permissible working pressure @ 30 degree Celsius, as per following Table No.2
Table No. 2 : Pressure Ratings (Reproduced from IS 4984)
c) The nominal diameter of pipes covered in IS 4984 are 16, 20, 25, 32, 40, 50, 63,
75,90, 110, 125, 140, 160, 180, 200, 225, 250, 280, 315, 355, 400, 450, 500, 560,
630, 710, 800, 900 and 1000 mm.
d) Pipes shall be designated according to the grade of material followed by pressure

rating and nominal diameter. For ex. PE 63 PN10 DN200 indicates a pipe
pertaining to material grade 63, pressure rating 1 MPa. & outside diameter 200
mm.
 Injection Moulded/Machined and Fabricated HDPE Fittings
All HDPE fittings / specials shall be of minimum PN 6 or above Pressure class.
Fabricated HDPE fittings shall be in accordance with IS:8360 (Part I to III). Injection
moulded/ machined fittings shall be as per IS: 8008 (Part I to IX). All fittings /specials
shall be moulded at factory only. No fabrication or moulding shall be allowed at site,
unless specifically permitted by the Engineer-In-Charge. Fittings shall be welded on to
the pipes or other fittings by use of Electro - fusion process.
When engineering HDPE fittings, the manufacturer can either use an injection
moulding or create a fabricated fitting. Generally speaking, injection moulds are used
to construct fittings up to 12” in diameter. Any fittings over 12” in diameter are
usually fabricated from sections of pipe or other parts. The larger fittings are
fabricated because their size exceeds injection moulding equipment capacities. Less
common fittings may also be fabricated because their low demand does not constitute
the creation of a mould.
816
Types of Injection Moulded / Machined HDPE Fittings
Various types of Injection Moulded/ Machined HDPE fittings are as given below.
1. 900 Bend
2. 900 Tee
3. Reducer
4. Ferrule Reducer
5. Pipe ends
6. Sand witch Flanges
7. Reducing Tees
8. End Caps
Types of Fabricated HDPE Fittings
Various types of fabricated HDPE fittings are as given below.
a) 900 Bend
b) 900 Tee

All pipes of the same size, same pressure rating and same grade and also
manufactured essentially under similar conditions of manufacture, shall constitute a lot. For
ascertaining conformity of the lot to the requirements of this specification, samples shall be
selected as per following.
 Dimensional and Visual Requirements
The number of test samples shall be in accordance with following Table No.3. These pipes
shall be selected at random from the lot and in order to ensure the randomness of selection, a
random number table shall be used. In the absence of a random number table, the following
procedure may be adopted.
Starting from any pipe in the lot, count them as 1,2,3,4, etc, up to r and so on where r is the
integral part of N/n, N being the number of pipes in the lot and n is the number of pipes in the
samples. Every rth pipe so counted shall be drawn so as to constitute the required sample size.
The number of pipes given for the first sample in col3 of Table No.3 shall be examined for
dimensional and visual requirements given in following para. A pipe failing to satisfy any of
these requirements shall be considered as defective. The lot shall be deemed to have satisfied
these requirements, if the number of defectives found in the first sample are less than or equal
to the corresponding acceptance number given in Col 5 of Table No.3. The lot shall be
deemed not to have met these requirements if the number of defectives found in the first
sample is greater than or equal to the corresponding rejection numbers given in col6 of Table
3. If, however, the number of defectives found in the first sample lies between the
corresponding acceptance and rejection numbers given in col. 5 and 6 of Table 3, the second
sample of the size given in col. 3 of Table 3 shall be taken and examined for these
requirements. The lot shall be considered to have satisfied these requirements, if the number
of defectives found in the cumulative sample is less than or equal to the corresponding
acceptance number given in co1 5 of Table 3; otherwise not.
817
Table No.3: Scale of Sampling for Visual and Dimensional Requirements
 Hydraulic Characteristics, Reversion, Overall Migration, Density, MFR and Carbon

Black Content/Dispersion Tests.
The lot having satisfied dimensional and visual requirements as mentioned above shall be
tested for hydraulic characteristics, reversion, overall migration, density, MFR and carbon
black content /dispersion requirements (as mentioned in following para. A separate sample
size for each of the test shall be taken as stipulated in following Table 4 and selected at
random from the sample already examined for dimensional and visual inspection. All the
pipes in each of the sample size shall be tested for compliance in the requirements for
hydraulic characteristics, reversion, overall migration, density, MFR, and carbon black
content /dispersion. The lot shall be considered to have met the requirements of these tests, if
none of samples tested fails.
818
Table No.4. Scale of Sampling for Tests for Hydraulic Characteristics, Reversion,
Overall Migration, Density, MFR and Carbon Black Content, Dispersion
For sample testing of injection moulded& fabricated specials, sampling criteria shall be as
mentioned in IS 8360 and IS 8008 respectively.
Pipe selected as per sampling criteria mentioned in earlier para are subject to following
tests before delivery from factory
1. Dimension: Outside diameter, Wall thickness, Length of pipe
3. Internal pressure creep rupture test,
4. Reversion test,
5. Overall migration test,
6. Density,
7. Melt flow rate (MFR),
8. Carbon black content and dispersion
These tests shall be carried out by the contractor in the presence of representative of
Engineer-In-charge /WRD/QC/TPI.
 Dimensions:
 Outside Diameter:
The outside diameter of pipes, tolerance on the same and ovality of pipe shall
be as given in following Table 5.
819
TableNo.5 Outside diameter, tolerance and ovality of pipes
(reproduced from IS 4984)
1) Outside diameter of the pipe shall be taken as the average of two measurements
taken at right angles for pipes up to 110 mm dia. Alternatively and for higher
sizes, the diameter shall be measured preferably by using a flexible Pi tape or
circometer, having an accuracy of not less than 0.1 mm.
2) Ovality shall be measured as the difference between maximum outside diameter

and minimum outside diameter measured at the same cross section of pipe, at 300
mm away from the cut end. For pipes to be coiled, the ovality shall be measured
prior to coiling.
 Wall thickness:
The wall thickness shall be measured by a dial Vernier or ball ended micrometer. The
minimum & maximum wall thickness of pipes of PE 63, PE 80 and PE 100 grade
material shall be as given in following table no. 6.
820
Table 6. Wall thickness of pipes for material grade PE 63, PE 80 and PE 100
All dimensions in mm.
 Length of straight pipe:

The length of straight pipe shall be 5 m to 20 m, as agreed between the
 Visual Appearance
The Internal and External surfaces of the pipes shall be smooth, clean and free
from grooving and other defects. The ends shall be cleanly cut and shall be square
with axis of the pipes. Slight shallow longitudinal grooves or irregularities in the wall
821
thickness shall be permissible provided that the wall thickness remains within the
permissible limits.
 Internal Pressure Creep Rupture Test:

When subjected to internal pressure creep rupture test in accordance with
procedure given IS 4984, the pipes under test shall show no signs of localised
swelling, leakage or weeping, and shall not burst during the prescribed test duration.
The temperatures, duration of test and induced stresses for the test shall confirm to
those specified in following table 7.
Table No.7: Requirements of pipe for Internal Pressure Creep Rupture Test
 Reversion Test
When tested according to the procedure given in IS 4984, value of the
longitudinal reversion shall not be greater than 3 %.
 Overall Migration Test

When tested from a composite sample of minimum 3 pipes as per IS 9845, the
overall migration of constituents shall be within the limits stipulated in IS 10146.
 Density
When tested from a composite sample of minimum 3 pipes as per IS 7328, it
shall meet the requirement as given in preceding para.
 Melt Flow Rate (MFR)

When tested from a composite sample of minimum 3 pipes as per IS 2530,at
190 degree Celsius with nominal load of 5 kgf, MFR shall be between 0.2 to 1.1 gram
/10 Minutes and also shall not differ by more than 30% of the MFR of the material
used in manufacturing pipes.
 Carbon Black Content & Dispersion

When tested from a composite sample of minimum 3 pipes as per IS 2530,
carbon black content shall be within 2.5 + 0.5 % and dispersion of carbon black shall
be satisfactory.
822
10. Grade of raw material
11. Pressure rating.
12. Nominal diameter
inscribed.
 Transportation of Pipe:
 When transporting straight polyethylene pipes, use flat bedded vehicles. The bed shall
be free from nails and other projections. The polyethylene pipes shall rest uniformly in
the vehicle over their long length.
 The vehicle shall have side supports approximately spaced 2 m apart, and the pipes
shall be secured effectively during the transportation. All posts shall be flat with no
sharp edges. Strapping the pipe bundles during transit may be required to avoid
excessive movement in the truck.
 Polyethylene pipes shall not be transported with other metallic items in the same
vehicle.
 Coiled pipe with outer diameter < 63 mm may be supplied on pallets. The coils should
be firmly strapped to the pallets, which in turn be firmly secured to the vehicle. Coiled
pipe with outer diameter ≥ 63 mm should be supplied individually.
 There should be facilities to ensure that each coil is securely fastened throughout
transit and the un-loading process.
 To save on transport cost nesting of coils/ straight lengths can be considered, if agreed
to between the purchaser and the supplier.
 Pipes manufactured at factory are to be carried to the site of work directly or stacked
suitably and neatly on contractors yard along the alignment/road side/elsewhere near
by the work site or as directed by the Engineer In-Charge.
 Stacking of Pipes at Site

The following precaution shall be taken so as to eliminate potential damage to pipes and
fittings and to maintain maximum safety.
 Pipes must not be stored or transported where they are exposed to heat sources likely to
exceed 60oC.
823
• Pipes shall be stored such that they are not in contact with direct sunlight, lubricating or
hydraulic oils, petrol, solvents and other aggressive materials.
• Scores or scratches to a depth of greater than 10% or more of wall thickness are not
permissible; any pipes having such defects should be strictly rejected.
• PE pipes should not be subjected to rough handling during loading and unloading operations.
Rollers shall be used to move, drag the pipes across any surface.
• Dragging pipes over rough ground should be avoided.
• Pipe shall be stacked on reasonable flat surface, free from sharp object, stone or projection
likely to deform or damage the pipes.
• Pipes shall not be dropped to avoid impact or bump. If any time during handling or during
installation, any damage, such as gouge, crack or fracture occurs, the pipe shall be repaired if
so permitted by the competent authority before installation.
• During coiling care should be taken to maintain the coil diameter at or above the specified
minimum to prevent kinks. Coiling shall be done when the pipe attains the ambient
temperature from the extruder. In uncoiling or recoiling care should be taken that sharp
objects do not scour the pipe.
• When releasing coils, it must be remembered that the coil is under tension and must be
released in a controlled manner. The end of the coil should be retained at all times, then the
straps released steadily, one at a time. If the coil has bands at different layers of the coil, then
they should be released sequentially starting from the outer layers.
 Valves
 Air Valve :
 Scour Valve :
 Control Valve :
824
G) Sliding Stem
 Globe valve
H) Rotary
 Butterfly valve
 Ball valve
I) Other
 Pinch valve
 Diaphragm valve

be conducted on random samples of pipes collected from site. These test shall be as per
those given below.

 Work of PDN shall be inspected, tested and certified by PMC/TPI/QC. Modalities of
PMC/TPI/QC Inspection shall be separately decided and given by Engineer-In-charge.
2. R.I.T.E.S. (Rail India Technical Economics Services)Mumbai
3. S.G.S, Mumbai
5. VJTI, Mumbai
6. CWPRS(Central Water & Power Research Station), Pune
of the samples to quality control authorities for test shall be provided free cost of
825

Quality Assurance.

2 Laboratory Assistants (Twelveth Pass with
Two to Four
(As per work)
(One for each L.A.)
 Following minimum equipments shall be available in the field laboratory setup

by the contractor.
Slump, & Cube Moulds, CTM
826
The other tests of mortar, concrete, sand, coarse aggregates etc. shall be carried out in
field laboratory set up by the contractor in presence of quality control representative
at contractors cost. Contractor shall through this procedure assure the quality of
work.
specification.
work.

representative of Engineer-In-charge /WRD/QC/TPI..
 While transporting straight polyethylene pipes, use flat bedded vehicles. The vehicle
shall have side supports approximately spaced 2 m apart, The bed shall be free from
nails and other projections. The polyethylene pipes shall rest uniformly in the vehicle
over their long length. Polyethylene pipes shall not be transported with other metallic
items in the same vehicle.
 Pipes at site shall be stored such that they are not in contact with direct sunlight,
lubricating or hydraulic oils, petrol, solvents and other aggressive materials.
suitably and neatly along the alignment/road side/elsewhere near by the work site or as
827
are required as per the detailed specifications or otherwise required by the Engineer-in-
Charge, the same shall be carried out at the laboratory, selected by the Engineer-in-

 The net length of pipes as laid or fixed shall be measured in running meters correct to a
cm. Specials shall be excluded and measured in running meters or numbers as
work.
 Excavation, refilling, anchor blocks, thrust blocks wherever required shall be

The break up to payment for supplying, laying and jointing of pipes shall be as under:-
C. 80% of the payment will be released after supplying, lowering, laying, Jointing and third
D. Balance 10% of the payment will be released after satisfactory hydraulic testing of
E. Remaining 10% amount will be withheld and it will be released after successful
respective WUAs.
15. After Successful Operation and Maintenance for First year-2%.
16. After Successful Operation and Maintenance for Second year-2%.
17. After Successful Operation and Maintenance for Third year-2%.
18. After Successful Operation and Maintenance for Fourth year-2%.
----------***----------
828
12.41 Lowering, Laying and Jointing H. D. P. E pipes in proper position
including all specials (Item No. LIPDN 50)
Lowering, Laying and Jointing H. D. P. E pipes in proper position including all specials by
compression fitting/electrofusion and butt fusion jointing procedure as per relevant IS Code
complete with all materials for jointing procedure like Electro fusion machine, Electric
heater/butt fusion welding machine with hydraulic jack, top loading clamp etc. and all labours
as directed by engineer in charge as per IS-7634 Part II For all classes.

testing at works and site of High Density Polyethylene Pipes used for water supply. Use of
HDPE Pipes of various diameters shall be as per relevant BIS /other standards marked with
Pressure class of PN 6.

clearing site and/or excavation shall rest with the Engineer In-charge. Useful material
shall be stacked as directed. The Contractor shall dispose off all unuseful materials as
directed by the Engineer In-charge.
 Demarcation
and labour required for lineout should be provided by the Contractor at his own cost. The
center line of excavation shall be clearly marked by pegs or by stones at each chain or
change of direction or at shorter intervals on curves, in the beginning. The final lineout
will be done by fixing references to neat suitable distances on either side of the center
line, beyond the canal edges so that they are not disturbed during the construction period.
The position of these stones will be marked on the cross section.
 Contractor shall provide and maintain the quarry roads and temporary roads required for

(a) Benchmarks fixed by the Survey of India and temporary benchmarks established by
benchmark.
829
Contractor.

2. Theodolites(Accuracy 1 second) 1No.
3. Levels 2Nos.
4. Staves 4Nos.
In-Charge.
Excavation for Pipe Trenches

drawing or as directed by Engineer In-charge. Contract or must assume all
materials to be excavated and the difficulties of making and maintaining the required
excavation. The trench width at bottom shall be 300 mm more than 1.5 times outside
pipe diameter. In any case trench width shall not be less than 500 mm.
 The usable excavated material available from the excavated trenches(PDN) shall be
Engineer In-charge. Unusful material from excavation shall be deposited in spoils as
and where directed by Engineer-In-charge.
 Surface or sub-soil water met with during trench excavation(PDN) and structure
material excavated under water level condition which requires intermediate stacking
for drying shall have to be re handled. No extra payment for efforts for drying out of
soil, re-handling of dry soil, etc. shall be given. No payment or extra efforts for
excavation under this condition shall be made.
additional excavation as stated here in above or as may be directed by the Engineer-
830
In-charge, shall be rectified at the cost of the Contractor. Filling and compaction for
such over excavation using the material as directed by the Engineer In-Charge shall
also be at the cost of the Contractor.
 In the PDN and structure section where expansive type of the soil such as CH type
of soil is encountered and over which PDN can not be directly laid, the PDN trench
and structure shall be over excavated to the extent as directed by the Engineer In-
Charge and such over excavated section shall be filled with suitable murum type soil
to be placed in uniformly compacted layers as directed by the Engineer In-Charge.
The over excavation made in such strata, filling by suitable soil, and watering and
Laying of Pipes
While laying of HDPE Pipes, all precautions as mentioned in IS 7634 shall be taken.
 Each pipe shall be thoroughly checked for any damages before laying and only pipes
that approved by Engineer-in-Charge shall be laid.
 The pipe line may be laid along side of the trench and jointed there. There after the
jointed pipeline shall be lowered into the trench carefully without causing undue
bending. The pipeline shall be laid inside the trench with a slack of up to 2 m/100 m
of pipe line.
 Polyethylene pipes conforming to IS 4984, being black in colour, when subjected to
direct sunlight or warm ambient temperature may become warmer than the ground
temperature. When placed inside the trench, the pipe will contract in length as it cools
to the surrounding soil temperature. If the pipe is connected to sub-surface structures
(such as preset valve, etc) before it is cooled sufficiently, excessive pull forces could
develop. Allow the pipe to cool to ambient temperature prior to making a connection
to an anchored joint.
 Polyethylene pipe requires no special bed preparation for laying the pipe underground,
except that there shall be no sharp objects around the pipe. However, while laying in
rocky areas suitable sand bedding should be provided around the pipe and compacted.
100 mm compacted fine sand bedding under and around the pipe be provided in rocky
areas.
 During the pipe laying of continuous fusion jointed systems, due care and allowance
should be made for the movements likely to occur due to the thermal
expansion/contraction of the material. This effect is most pronounced at end
connections to fixed positions (such as valves etc.) and at branch connections. Care
should be taken in fixing by finishing the connections at a time the length of the pipe
is minimal (lower temperature times of the day).
 The flexibility of polyethylene pipes allows the pipe to be cold bend. The fusion
jointed PE pipe is also flexible as the plain Pipe. Thus the total system enables
directional changes within the trench without recourse to the provision of special
bends or anchor blocks. However, the pipe should not be cold bend to a radius less
than that mentioned in IS 7634 (Part-II).
 The Installation of flanged fittings such as connections to sluice/air/gate valves and
hydrant tees etc., requires the use of stub ends (collars/flange adaptors) complete with
backing rings and gaskets. Care should be taken when tightening these flanges to
provide even and balance torque.
831
Provision should be made at all heavy fittings installation points for supports (such as
anchoring of the flange in the soil) for the flange joint to avoid the transfer of valve
wheel turning torque on to the PE flange joint
 The pipe shall be laid on a stable foundation. Where water is present or where the
trench bottom is unstable, excess water should be removed before laying the pipe. In
case there is a chance of floatation because of likely flood, the pipe shall be encased
with concrete weights as per the buoyancy calculations.
 Under National / State Highways, a concrete / Hume pipe shall be covered over the
pipe.
 Polyethylene pipes are non-metallic, so once buried, metal detector type locators are
ineffective. To facilitate locating a buried PE pipe, metallic locating tapes or copper
wires can be placed alongside the pipe. Locating tapes/wires are placed slightly above
the crown of the pipe before the final back fill.
Because of high integrity of properly made fusion joints, PE pipes can be used
with special installation techniques such as horizontal directional drilling, pipe
bursting, micro tunnelling methods of trench less technologies.
Jointing of pipes should be done as per Procedure mentioned in IS 7634.Thecommonly
used joints are as follows:
a) Fusion welding:
1) Butt fusion welding; .
2) Socket fusion welding;
3) Electro fusion welding;
b) Insert type joints;
c) Compression fittings/push fit joints;
d) Flanged joints
e) Spigot and socket joints.
The detailed Jointing Procedure of above mentioning various joints shall be as per IS
7634 (Part-II)
 Fusion Welded Joints

The principle of fusion welding is to heat the two pipe surfaces to a designated
temperature and then fuse them together by application of sufficient force. This force
causes the melted materials to flow and mix, there by resulting in fusion.
Fusion welding of PE pipes must be carried out with welding equipment
having temperature and pressure (where applicable) display arrangements. PE pipes
and PE fittings, to be joined by face-to-face (butt fusion) welding must be of the same
wall thickness and the ends must be cut square. However, in some cases of fusion,
where face-to-face contact is not involved the jointing pipes/fittings wall thicknesses
need not be same. The integrity of the fusion joint is dependent on the cleanliness,
temperature control and designated equipment that has been properly maintained.
The pipe ends shall be dry and free of dust. Mating surfaces shall be
planed/scraped before fusion to remove surface material as polyethylene (PE) oxidizes
on exposure to air. These prepared (scraped) surfaces should not be touched, as there
is a risk of contamination of the surface, which may affect the weld efficiency.
832
 Insert Type Joint
• Insert type of fittings are available in both plastic and metal for use with PE pipes.
These are commonly used for the delivery pipe connections of bore/tube well
pumps.
• In corrosive locations plastic/stainless steel insert fittings are preferred. In less
corrosion conditions gunmetal fittings may be used and in normal or slightly
corrosive environments, brass fittings may be employed. The insert moulding
plastic fittings with metallic inserts are also available. The outer serrations of
PE/metal insert type fittings-slightly over sized-lock into the pipes to prevent their
coming out under sudden pressure surge. The pipe bore is expanded by immersion
in oil bath (130°C) where the heat of the oil bath would soften the pipe to enable
insertion of fitting.
• This type of jointing is used normally for pipe diameters up to 110 mm and
internal pressure below 0.4 MPa.
 Compression Fittings
o Compression fittings are detachable joints and are made of metal or plastics
[polypropylene (PP)] or a combination of both. Compression fittings form a tight
seal by applying a compressive force to the pipe and pipe fitting. The fitting is
compressed against the pipe with a force sufficient to eliminate all space
remaining in the joint, thus preventing the fluid from leaking.
o It is critically important to the integrity of the fitting that excessive force is
avoided in tightening the nut. If the fitting is over tightened, the gripper (clip
ring) will deform and cause leaks. Over tightening is the most common cause of
leaks in compression fittings. As a general rule, a compression fitting should be
‘finger tight’ and then tightened one turn with a wrench. The fitting should then
be tested, and if slight weeping is observed, the fitting should be slowly
tightened a bit more until the weeping stops.
o Compression fittings are especially useful in installations that may require
occasional disassembly or partial removal for maintenance, etc, since these
joints can be detached and re-joined without affecting the integrity of the joint.
They are also used in situations where a heat source, in particular a heating plate,
is prohibited and inside bead formation by butt fusion is not preferred.
o For coiled polyethylene pipes, of small diameters (Less than 110 mm) where the
working pressure do not exceed 1.6 MPa, jointing by polypropylene (PP)
compression fittings is generally recommended over fusion jointing.
 Flanged Joints
1. These are used for jointing the PE pipes particularly of larger size to valves and
vessels and large size metal pipes, and where non-PE pipes are to be joined with
PE pipes.
2. It contains slip-on metallic/polyethylene flanges with collar/stub ends. The
collar/stub end is welded by butt, socket or electro fusion. In case polyethylene
flanges are used a suitable metallic backing plates shall be used to support the
polyethylene flanges so that the bolt force does not deform the plastic flange.
Sealing is improved by incorporating a natural or synthetic rubber gasket
between the flanges.
833
 Spigot and Socket Joint
 Any joint that permits sliding of the free end (spigot end) inside the socket with a
rubber or suitable gasket, without leakage is called a spigot and socket joint.
 The socket (bell) could be an integral part of the pipe at one end or a special
coupler, into which the free ends (spigot ends) of the pipes are pushed to achieve a
water tight joint. Various types of ‘O’ rings are available in the market and the
user may check with the manufacturer about the suitability of the same as per site
conditions.
 These joints are normally weak in longitudinal pull and hence need anchoring
wherever such a tendency of longitudinal pull is likely in the pipe line.
 This type of joint is best used for non-pressure applications, such as gravity lines
and for encasing cables or smaller diameter pipes.
shall be subject to approval by Engineer-in-Charge.
as prescribed in this paragraph or as directed by the Engineer-in-Charge.
equipment will depend on nature of material, the height and load assumed in design
of structure. The backfill close to the structure up to the rolled layer shall be
compacted in suitable uniform layers, using pneumatic / hand tampers as appropriate
for dry density at average bulk density (+/- 10%). The moisture content of the earth
fill placed against the rock or the structure shall be on higher/lower side of OMC by
about 2% or so, to allow it to be compacted. Profuse watering shall be done to
pervious materials (sand) before compaction as per instruction of the Engineer-in-
Charge. Compaction at junction of earthwork and backfill around the structure shall
be carried out with special care.

boundaries so as they will not be disturbed during the agricultural activities of
the farmers.
 The marking shall be constructed in prefabricated concrete block of size
(15x15x45) CM embedded in concrete block of size (30x30x30)CM. The base
834
of this block shall be buried in ground projecting only 15cm above the ground
and the base concrete block.
 These blocks shall be able to locate the pipeline as and where it is laid all over
the work. The contractor shall mark each block with specific distinct
identification mark.
 The contractor shall show all this blocks jointly to the Engineer in-charge or his
representative, representative of WUA, concern farmers sharing the boundaries,
TPI, any other stake holders in the command.
 Contractor shall maintained these blocks in proper order during operation &
maintenance period of this contract. Any damage done to these blocks for the
 The contractor shall submit the location of such blocks with specific
identification marks with schedule on a special command area map.
 The map of marking of the block shall be handed over to WUA while handing
over the command area.
 The Geotagging map showing Latitude and Longitude Value of each apex of
laid pipeline shall be submitted to Department and WUA for future reference.
 The contract shall fix information boards of 1.2 m x 0.9 m size at various location
as directed by Engineer-in-charge. On this boards, salient features of the work
(eg. Pipe diameter, pipe type, discharge, any other specific details suggested by
Engineer-In-Charge) shall be written.

2. R.I.T.E.S. (Rail India Technical Economics Services) Mumbai
3. S.G.S, Mumbai
5. VJTI, Mumbai
835

Quality Assurance.

2 Laboratory Assistants (Twelveth Pass with
Two to Four
(As per work)
(One for each L.A.)

by the contractor.
836

The other tests of mortar, concrete, sand, coarse aggregates etc. shall be carried out
infield laboratory setup by the contractor in presence of quality control representative
at contractors cost. Contractor shall through this procedure assure the quality of
work.
specification.
work.

837
Engineer In-charge.
 While laying of HDPE Pipes, all precautions as mentioned in IS 7634 shall be taken.
drawings.
 Each pipe shall be thoroughly checked for any damages before laying and only pipes
that approved by Engineer-in-Charge shall be laid.
 The pipe line may be laid along side of the trench and jointed there. There after the
jointed pipeline shall be lowered into the trench carefully without causing undue
bending. The pipeline shall be laid inside the trench with a slack of up to 2 m/100 m
of pipe line.
 Jointing of pipes should be done as per Procedure mentioned in IS 7634.
 Pipe embedment back fill shall be stone-free excavated material.
838
 Compaction at junction of earthwork and backfill around the structure shall be
of the farmers.

The net length of pipes as laid or fixed shall be measured in running meters correct to a cm.

Payment
The break up to payment for supplying, laying and jointing of pipes shall be as under:-
A) 80% of the payment will be released after supplying, lowering, laying, Jointing
of respective WUAs.
----------***----------
839
12.42 Providing and supplying ISI mark H. D. P. E pipes fitting / specials ( Item
No. LIPDN 51 )
Providing and supplying ISI mark H. D. P. E pipes fitting/specials including loading,
unloading, transportation up to departmental store, stacking excluding GST levied by GOI &

This specification covers the requirements for providing and supplying ISI mark H. D. P. E
pipes fitting/specials including loading, unloading, transportation upto departmental store,
stacking excluding GST levied by GOI & GOM in all respect.

 Introduction
HDPE pipe is a type of flexible plastic pipe used for fluid and gas transfer. HDPE material
is a polyethylene thermoplastic made from petroleum and its high level of impermeability
and strong molecular bond makes it suitable for high pressure pipelines. The toughness
and resistance to chemicals as well as the corrosion resistance and low weight have
contributed to its growing use in situations where cost effective and durable fluid and gas
pipe systems are required. HDPE pipe is made from food grade polyethylene virgin
material as such they are safe for the transfer of potable water.
The Contractor shall provide on-site training on HDPE pipe laying, jointing, testing and
maintenance etc., to the personnel authorized by Engineer-in-Charge. The contractor
should provide technical Manual on HDPE pipes including precautions to be taken during
 Applicable IS -Codes, ISO Codes

The manufacturing, testing, supplying, laying, jointing and testing at work sites of HDPE
HDPE Pipes form part of these Specifications.
840
IS 4984 High Density Polyethylene Pipes for Water Supply
ISO 4427 HDPE pipes and fittings for water supply.
IS 8360 Specifications for fabricated HDPE fittings for potable water
supplies.(Part I to III)
IS 8008 Injection moulded/ machined HDPE fittings for potable water
supplies.(Part I to IX)
IS 7634 Part-II Laying & Jointing of Polyethylene (PE) Pipes
IS 7328 High density polyethylene materials for moulding and extrusion
IS 2530 Methods of test for polyethylene moulding materials and compounds.
IS 10141 Positive lists of constituents of polyethylene in contact with food stuffs,
pharmaceuticals and drinking water.
IS 9845 Method of analysis for the determination of specific and/or overall
migration of constituents of plastics material and articles intended to
come in to contact with food stuffs
IS 10146 Polyethylene for its safe use in contact with food stuff, Pharmaceuticals
and drinking water.
 Raw Materials
Raw material used to manufacture the HDPE Pipes is High Density Polyethylene of PE
63, PE 80 and PE 100 grade.
 The material used for the manufacturer of pipes should not constitute toxicity hazard,
should not support microbial growth, should not give rise to unpleasant taste or odour,
cloudiness or discoloration of water. Pipe manufacturers shall obtain a certificate to
this effect from the manufacturers of raw material as per the satisfaction of the
Engineer-in-Charge.
 High density Polyethylene (HDPE) used for the manufacture of pipes shall conform to
designation PEEWA-45-T-003 or PEEWA-45-T-006 or PEEWA-50-T-003 or
PEEWA-50-T-006 or PEEWA-57-T-003 or PEEWA-57-T-006 of IS 7328. HDPE
conforming to designation PEEWA-45-T-012 or PEEWA-50-T-012 or PEEWA-57-T-
012 of IS 7328 may also be used with the exception that Melt Flow Rate (MFR) shall
be between 0.20 to 1.10g/10min. In addition the material shall also confirm to clause
5.6.2of IS 7328.
 The Specified base Density shall be between 940.5 to 958.40 kg/cm3(both inclusive)
determined at 270C according to procedure prescribed in IS 7328. The value of
density shall not differ from the nominal/agreed value by more than 3 kg/m 3.
 The Melt Flow Rate (MFR) of the material shall be between 0.20 and 1.10gm/10min.
(both inclusive) when tested at 190°C with nominal load of 5kgf as determined by
method prescribed in IS2530. The MFR of the material shall also be within±20
percent of the value declared by the manufacturer.
 The resin shall be compounded with carbon black. The carbon black content in the
material shall be within 2.5±0.5% and the dispersion of carbon black shall be
satisfactory when tested as per procedure described in IS2530.
841
 The percentage of anti-oxidant used shall not be more than 0.3 percent by mass of
finished resin. The anti-oxidant used shall be physiologically harmless and shall be
selected from the list given in IS 10141.
 The addition of not more than 10 % of the manufacturer's owner work material
resulting from the manufacture of pipes is permissible. No other reworked or recycled
material shall be used.

To make pipe lengths, HDPE material is heated and extruded through a die, which determines
the diameter of the pipeline. The wall thickness of the pipe is determined by a combination of
the size of the die, speed of the screw and the speed of the haul-off tractor. The General
manufacturing process of HDPE Pipe is as given the below.
• Polyethylene raw material is pulled from a silo, into the hopper dryer, which
removes any moisture from the pellets.
• Then it is pulled by a vacuum pump into blender, where it is heated by a barrel
heater. The PE material becomes molten at around 180 degrees Celsius, allowing it
to be fed through a mould/die, which shapes the molten material into a circular
shape.
• After coming through the die, the newly formed pipe quickly enters the 3-4 cooling
tanks, which submerge or spray water at the pipe exterior, each one reducing the
temperature of the pipe by 10-20 degrees.
• Because Polyethylene has a high specific heat capacity, the pipe must be cooled in
stages, to avoid deforming the shape, and by the time it reaches the 'haul-off
tractor', it is hard enough to be gently pulled by the 2-3 belts.
 Workmanship/Appearance
Pipes shall be free from all defect including in dentations, delaminating, bubbles,
pinholes, cracks, pits, blisters, foreign inclusions that due to their nature, degree of extent
detrimentally affect the strength and serviceability of the pipe. The pipe shall be as
uniform as commercially practicable in colour opacity, density and other physical
properties as per relevant IS Code or equivalent International Code. The inside surface of
each pipe shall be free of scouring, cavities, bulges, dents, ridges and other defects that
result in a variation of inside diameter from that obtained on adjacent unaffected portions
of the surface. The pipe ends shall be cut clearly and square to the axis of the pipe.
 Classification of Pipes:
 Pipes shall be classified according to the grade of materials as given in following
Table No.1.
842
Table No.1: Classification of Pipe material (Reproduced from IS 4984)
Sr.No. Material grade MRS ( Minimum required Maximum allowable

strength) of material in MPa hydrostatic design stress
(N/mm2)., @20 Degree Mpa. (N/mm2)
Celsius, 50 years
At 20 degree Celsius
1 2 3 4
i) PE 63 6.3 5.0
ii) PE 80 8.0 6.3
iii) PE 100 10.0 8.0
 Pipe shall be classified by pressure rating (PN) corresponding to the maximum

permissible working pressure @ 30 degree Celsius, as per following Table No.2
Table No. 2 : Pressure Ratings (Reproduced from IS 4984)
 The nominal diameter of pipes covered in IS 4984 are 16, 20, 25, 32, 40, 50, 63,
75,90, 110, 125, 140, 160, 180, 200, 225, 250, 280, 315, 355, 400, 450, 500, 560, 630,
710, 800, 900 and 1000 mm.
 Pipes shall be designated according to the grade of material followed by pressure

rating and nominal diameter. For ex. PE 63 PN10 DN200 indicates a pipe pertaining
to material grade 63, pressure rating 1 MPa. & outside diameter 200 mm.
 Injection Moulded /Machined and Fabricated HDPE Fittings

All HDPE fittings / specials shall be of minimum PN 6 or above Pressure class. Fabricated
HDPE fittings shall be in accordance with IS : 8360 (Part I to III). Injection moulded/
843
machined fittings shall be as per IS: 8008 (Part I to IX ). All fittings /specials shall be
moulded at factory only. No fabrication or moulding shall be allowed at site, unless
specifically permitted by the Engineer-In-Charge. Fittings shall be welded on to the pipes
or other fittings by use of Electro - fusion process.
When engineering HDPE fittings, the manufacturer can either use an injection
moulding or create a fabricated fitting. Generally speaking, injection moulds are used to
construct fittings up to 12” in diameter. Any fittings over 12” in diameter are usually
fabricated from sections of pipe or other parts. The larger fittings are fabricated because
their size exceeds injection moulding equipment capacities. Less common fittings may
also be fabricated because their low demand does not constitute the creation of a mould.
 Types of Injection Moulded / Machined HDPE Fittings

Various types of Injection Moulded/ Machined HDPE fittings are as given below.
a) 900 Bend
b) 900 Tee
c) Reducer
d) Ferrule Reducer
e) Pipe ends
f) Sandwich Flanges
g) Reducing Tees
h) End Caps
 Types of Fabricated HDPE Fittings

Various types of fabricated HDPE fittings are as given below.
1. 900 Bend
2. 900 Tee
 Valves
 Air Valve :
 Scour Valve :
drain pipeline.
844
 Control Valve :
A) Sliding Stem
 Globe valve
B) Rotary
 Butterfly valve
 Ball valve
C) Other
 Pinch valve
 Diaphragm valve

 All HDPE fittings/ specials shall be of minimum PN 6 or above Pressure class, fabricated
in accordance with IS: 8360 (Part I & III).
 All fittings/specials shall be fabricated or moulded at factory only. No fabrication or
moulding will be allowed at site, unless specifically permitted by the Engineer-in-Charge.
Fittings will be Butt welded on to the pipes or other fittings by use of Electro/Butt fusion
process. Recommended makes for PE / PP fittings / specials are Georg-Fischer / Glynwed
/ Frialen / Durafuse if purchased or should be manufactured by the manufacturer himself
to have consistency with pipe material/grade.
 Jointing between HDPE pipes and specials shall be done as per the latest IS: 7634 part II.
 Method of jointing between the pipes to pipes and pipes to specials shall be with Electro
or Butt-fusion welding using automatic or semi-automatic, hydraulically operated,
superior quality Electro/Butt-fusion machines which will ensure good quality welding of
HDPE pipes.
 Normally Electro/Butt fusion welding shall include following activities:
- Aligning of pipe on welding M/C
- Surface preparation for welding.
- Heating of pipes/ ends
Holding pipes for welding
- Cooling etc.

 Measurement
The net length of pipes as laid or fixed shall be measured in running meters correct to
a cm. Specials shall be measured in running meters as specified by Engineer-in-charge
and paid for separately under the relevant item. The portion of the pipe overlapped at
the joints shall not be included in the length of pipe work. Excavation, refilling,
845
anchor blocks, thrust blocks wherever required shall be measured and paid for

Payment
The break up to payment for supplying, laying and jointing of pipes shall be as
under:-
 80% of the payment will be released after supplying, lowering, laying, Jointing and
 Balance 10% of the payment will be released after satisfactory hydraulic testing of
 Remaining 10% amount will be withheld and it will be released after successful
respective WUAs.
----------***----------
846
12.43 Hydraulic testing of H. D. P. E. pipe line to specified pressure (Item No.
LIPDN 52)
Hydraulic testing of H. D. P. E. pipe line to specified pressure including cost of all materials
and labour and water for testing for specified length including cutting, placing end cap
making arrangement for filling safe water using reciprocating type pumps which should be
able to provide specified test pressure gauges and other necessary equipments, labour,
operation charges, etc. required for testing. The rate under this item shall also include cost of
retesting, if necessary and reinstating to original position.
This specification covers the requirements for hydraulic testing at works and site of High
Density Polyethylene Pipes used for water supply. Use of HDPE Pipes of various diameters
shall be as per relevant BIS /other standards marked with Pressure class of PN 6.
 Field Testing Of Pipeline System

 The pipeline to be tested shall be filled with water slowly allowing for splurging the
entrapped air. Air valves at high points should be open to allow air to escape while
water is being filled. Before pressure is applied, the pipeline section under test shall be
restrained against movement.
The following procedure needs to be followed for HDPE pipe testing

a) Polyethylene pipelines shall be pressure tested at ambient temperature. After
filling with water the pipeline shall be left to stabilize for a period of 1 hour.
b) Fusion joints may be covered during testing. Flanged joints shall be kept open for
visual inspection. The pipeline shall be filled with water and pressure tested from
the lowest point.
c) During the test period, make-up water is continuously added to maintain the
pressure.
d) The test pressure shall be 1.5 times the rated pressure of pipes or of the proposed
maximum design pressure of the section. Apply the pressure by continuously
pumping at a constant rate.
e) Under no circumstance, air is to be used instead of water for testing.
f) Tests should be performed on reasonable lengths of pipelines. Long lengths more
than 2 000 m may make leak detection more difficult.
g) Acceptance criteria — If the pressure remains steady (within 5 percent of the
target value) for 1½ h, leakage is not indicated.
h) If the test is not complete because of leakage or equipment failures, the test
section shall be depressurized and allowed to relax for at least 8 h, before starting
the next testing sequence.
i) Testing outside the trench is to be avoided, as pipe rupture may involve safety
issues.
 If any leakage is found during testing of pipeline, Contractor will have to attend the
same immediately and rectify at his cost within. If Contractor fails to rectify the
defect, the entire length of pipeline between two adjacent outlets shall be rejected. If
847
any intermediate payment is made to the Contractor for portion under rejection, the
same shall be recovered from the outstanding dues of the Contractor.

2. R.I.T.E.S. (Rail India Technical Economics Services)Mumbai
3. S.G.S, Mumbai
5. VJTI, Mumbai
1. All materials before being utilized in works shall be inspected and tested, by the
2. The materials shall be tested in QC laboratory or at any other place directed by the
3. Testing charges for testing of Cement, TMT bars, all types of pipes and specials
4. The Contractor shall make suitable arrangements to see that one of his
848

 Following minimum persons shall be employed by the contractor at work site

2 Laboratory Assistants (Twevlth Pass with
Two to Four
(As per work)
(One for each L.A.)

by the contractor.


infield laboratory set up by the contractor in presence of quality control
quality of work.
 The materials, mixes and any other arrangements, including lab ours, shall be
supplied by the contractor. The samples for testing shall be taken in the presence of
Engineer-in-Charge or his representative /QC present on site. The contractor or his
authorized representative shall have a free access in these laboratories, to get himself
satisfied about procedures of test in etc. Even if the contractor or his representative
fails to remain present while collecting samples or testing, the results will be
considered as authentic and binding on the contractor.
849
specification.
work.

 Polyethylene pipelines shall be pressure tested at ambient temperature. After filling
with water the pipeline shall be left to stabilize for a period of 1 hour.
 Fusion joints may be covered during testing. Flanged joints shall be kept open for
visual inspection. The pipeline shall be filled with water and pressure tested from the
lowest point.
 During the test period, make-up water is continuously added to maintain the pressure.
 The test pressure shall be 1.5 times the rated pressure of pipes or of the proposed
maximum design pressure of the section. Apply the pressure by continuously
pumping at a constant rate.
 Under no circumstance, air is to be used instead of water for testing.
 Tests should be performed on reasonable lengths of pipelines. Long lengths more
than 2 000 m may make leak detection more difficult.
 Acceptance criteria — If the pressure remains steady (within 5 percent of the target
value) for 1½ h, leakage is not indicated.
 If the test is not complete because of leakage or equipment failures, the test section
shall be depressurized and allowed to relax for at least 8 h, before starting the next
testing sequence.
 Testing outside the trench is to be avoided, as pipe rupture may involve safety issues.
same immediately and rectify at his cost within. If Contractor fails to rectify the
defect, the entire length of pipeline between two adjacent outlets shall be rejected. If
any intermediate payment is made to the Contractor for portion under rejection, the
same shall be recovered from the outstanding dues of the Contractor.
 Third Party Inspection of PDN work shall be inspected, tested and certified by

 Measurement
The net length of pipes as laid or fixed shall be measured in running Kilometres
correct to a meters. Specials shall be excluded and measured in running meters or
numbers as specified by Engineer-in-charge and paid for separately under the relevant
item. The portion of the pipe overlapped at the joints shall not be included in the
length of pipe work. Excavation, refilling, anchor blocks, thrust blocks wherever
850
Payment
The break up to payment for supplying, laying and jointing of pipes shall be as
under:-
A. 80% of the payment will be released after supplying, lowering, laying, Jointing
B. Balance 10% of the payment will be released after satisfactory hydraulic testing of
C. Remaining 10% amount will be withheld and it will be released after successful
of respective WUAs.

----------***----------
Note :-
 The contractor shall operate and maintain the complete pipe distribution network for the
period of 5 (five) years after commissioning. Out of this period, during last two years the
operation of the schemes shall be done by the contractor jointly along with WUA. On
completion of O & M period, the system shall be handed over to WUA.
 During rotation period, once in every year, the Contractor shall perform hydraulic
 On completion of every Irrigation season, the contractor shall flush the pipe line from its
tail flush valve so that any siltation, vegetation or obstruction is cleaned and pipe is able
to flow designed discharge for next season.
 During the O & M period, contractor shall give training to the members of WUA about O
& M of PDN work and its efficient use and protection of the system from any damages.
 The contractor shall prepare a detail map of the permanent marking along the alignment
record to WUA. Along with this, the detailed Geotagged map of laid pipeline shall be
handed over to WUA.
 In association of the members of WUA, the Engineer In-charge shall confirm the release
851
SPECIFICATION FOR PRESTRESSED CONCRETE CYLINDER PIPES (PCCP)
12.44 Providing and supplying Pre-stressed Concrete Cylinder Pipes ( Item No.
LIPDN 53)
Providing and supplying Pre-stressed Concrete Cylinder Pipes suitable for sliding overlap
weld joint or confined rubber ring joint with necessary rubber ring of following class and
diameter including cost of transportation, inspection charges to store, transit insurance,
unloading and stacking excluding GST levied by GOI & GOM in all respect etc. complete.

This Specification covers the requirements of pre-stressed Cylinder concrete pipes with
nominal internal diameter 10 the range of 200 mm to 2 500 mm in which permanent Internal
stresses are deliberately introduced by tensioned steel to the desired degree to counteract the
stresses caused in pipe under service.

 Introduction
The Pre-stressed Concrete Cylinder Pipe (PCCP) comprises of a welded sheet steel cylinder
with steel socket and spigot rings welded to its ends, lined with concrete suitably compacted
and circumferentially pre-stressed to withstand internal pressure and external design load.
PCCP pipe is subsequently coated with cement mortar to protect the steel cylinder and pre-
stressing wires.
The Contractor shall provide on-site training on PCCP pipe laying, jointing, testing and
provide technical Manual on PCCP pipes including precautions to be taken during operation
of the pipeline.
The manufacturing, testing, supplying, laying, jointing and testing at work sites of PCCP
pipes shall comply with all currently applicable statutes, regulations, standards and Codes. In
Codes not specifically mentioned here but pertaining to the use of PCCP Pipes form part of
852
Part 1&2 Concrete.
Concrete
 Raw Materials
Raw materials used to manufacture PCCP Pipes are cement, aggregates, water, admixture,
steel reinforcement, steel for cylinders and specials.
 Cement
The cement used in the manufacture of PCCP pipes shall conform to one of the following.
 43/53 grade Ordinary Portland Cement conforming to IS:8112/IS 12269

 Rapid Hardening Portland cement conforming to IS: 8041
 Portland Slag cement (with not more than 50% slag) conforming to IS: 455
 Sulphate resisting Portland Cement conforming to IS: 12330
 Aggregate
The coarse and fine aggregates shall conform to I.S.383. The maximum size of aggregate
shall not exceed one third the thickness of the pipe or 20mm whichever is smaller. Silt
Content in fine aggregates shall be less than 3 percent. The fineness modulus of aggregates
for coating shall be between 2.6 to 3.2.
 Water
The water used in the preparation of concrete mix shall be clean and free from harmful or
injurious compounds such as acids, alkali, oil, organic material or other substances and
shall conform to the requirements of mixing water as per IS : 456.
 Admixtures
conform to IS 9103.
853
 Steel reinforcement
 Prestressing steel wire shall conform to IS 1785.
 Un tensioned reinforcement may consist of MS bars conforming to IS432
or HYSD bar conforming to 1786
 Steel plates for Cylinders, Joint rings and Specials

Steel plates for cylinders, joint rings and Specials shall conform to IS: 2062

The Manufacturing of pipes and specials for PCCP pipes shall be as per IS 784. The mould
and method of manufacture of pipe shall be such that the form and dimensions of the finished
pipe conform to IS 784 and the surface and edges of the pipes are clean and true. Various
steps involved in pipe manufacturing process are as given below.
 Fabrication & hydrostatic testing of steel cylinder as per required size

 Welding of steel socket and spigot rings to end of steel cylinder.
 Placing of concrete in the core either by the centrifugal method or vertical casting method (
Minimum cement content - 350kg/m3, Maximum W/C ratio - 0.5 and Minimum
compressive strength at 28 days, - 40 N/mm2)
 Rich cement mortar out coating (Cover coating) on pipe. (minimum cement content-
540kg/m3 , minimum water cement ratio – 0.27, minimum compressive strength of cement
mortar at 28 days-35 N/mm2).
 Curing of pipe.
Cross-section of PCCP Pipe Joint
PCCP pipe shall be designed to withstand the combined effects of internal water pressure &
external loads. Design of PCCP pipes shall be site specific as internal water pressure will
854
separately for sampling and evaluation, for conformity to the requirements of IS 784 Scale of
sampling shall be as given in following Table No.1.
Table No.1 Scale of Sampling and No. of Acceptable defective tests

Pipe selected as per sampling criteria mentioned in above para 5.0 are subject to following
5) Steel Cylinder Test.

6) Dimensions - Length, Internal diameter, Core thickness, straightness and finish.
7) Hydrostatic Factory Test
8) Permeability Test on Coating
9) Mortar soundness test
 Steel Cylinder Test: During manufacturing, each steel cylinder with steel and spigot rings
welded on shall be subjected to water pressure which stresses the steel to at least 140
N/mm2but not more than 175 N/mm2. While under stress, the assembly, especially welds
shall not show any leakage. If any leakage is found, assembly shall be repaired and whole
assembly retested.
 Dimensions
 Length -
Length of Pipe shall be 2m to 6m. For pipes up to and including 300mm
diameter, the length shall not be more than 3m.
 Nominal internal diameter of the pipe and minimum core thickness shall be as
per following Table No. 2
855
Table 2 Nominal Internal Diameter and Minimum Core Thickness of Pipes
Nominal Internal Minimum Core Nominal Internal Minimum Core

Diameter of Pipe Thickness Diameter of Pipe Thickness
(mm )
(mm ) (mm ) (mm )
200 35 1300 75
250 35 1400 75
300 35 1500 80
350 35 1600 85
400 35 1700 90
450 35 1800 95
500 35 1900 100
600 40 2000 105
700 40 2100 110
800 45 2200 115
900 55 2300 120
1000 60 2400 125
1100 65 2500 130
1200 70 - -
 Minimum wall thickness of steel cylinders shall be 1.6 mm

 The minimum thickness of plates for steel socket & spigot joint rings shall be as per
following Table No.3
856
Table No.3 : Minimum wall thickness of joint rings.
Nominal Internal Diameter Minimum wall thickness of joint
rings.(mm )
(mm )
200 5.0
250 5.0
300 5.0
350 5.0
400 5.0
450 5.0
500 5.0
600 5.0
700 5.0
800 5.0
900 5.0
1000 7.0
1100 7.0
1200 8.0
1300 8.0
1400 8.0
1500 8.0
1600 10.0
1700 10.0
1800 10.0
1900 12.00
857
Nominal Internal Diameter Minimum wall thickness of joint
rings.(mm )
(mm )
2000 12.00
2100 12.00
2200 12.00
2300 14.00
2400 14.00
2500 14.00
 The deviation from straight line taken between two points one meter apart,
along the pipe barrel shall not exceed 5mm.
 The pipe shall be free from local depressions or bulges greater than 5mm
extending over a length, in any direction.
 Hydrostatic Factory Test
The pipe shall be subjected to hydrostatic test after coating in accordance with IS 3597.
For this test, the pipe is placed on a hydrostatic test bench, filled with water and pressure
has to be raised slowly up to designed factory test pressure. Pressure shall be maintained
by pumping water as per IS 3597.
The pipe must not show leakage Damp or wet patches shall be accepted. If the pipe fails to
pass the test, it can be cured or repaired to improve its water tightness and then retested. In
case the pipe does not stand the rated internal pressure, it shall be accepted for lower
pressure to which it withstands, at the discretion of Engineer-in-charge, provided all other
requirements are conforming to this standard.
 Permeability Test on Coating
method described in IS 3597 shall not exceed 2 cm3 at the end of two hours and the final
permeability between fourth and fifth hours shall not exceed 0.3 cm3. When a higher result
is obtained, the test shall be repeated on twice the number of pipes originally tested and the
lot shall be accepted, if all pipes pass the test. Where retest is not satisfactory, all pipes
from that lot may be tested individually and only those with satisfactory results shall be
accepted. No additional treatment of any type shall be allowed on the pipe before
permeability test is taken. The test shall be done immediately after the hydrostatic factory
test. In case this is done later, then the pipe has to be kept wet for 48 hrs prior to test.
 Mortar soundness test
After the mortar coating is cured and prior to transport, the coating on each pipe shall be
checked for delamination and hollows by tapping the exterior with hammer having head of
mass of not more than 0.5 kg. Any hollows or drumming areas detected by sounding shall
be repaired by approved method.
858
2. Pressure rating.
3. Nominal diameter
8. Any other important matter that the manufacturer or purchaser deems fit to be inscribed.
 The vehicle shall have side supports approximately spaced 2m apart, and the pipes shall be
secured effectively during the transportation. All posts shall be flat with no sharp edges.
 A pipe section must be rolled or otherwise moved, such operation shall be done slowly and
with every reasonable precaution against damage. Any portion of the lining, coating that
may become damaged shall be repaired with polymer Mortar.
 All pipes shall be loaded in trucks by mechanical crane/ tripod and unloaded carefully
using crane/ tripod. No unloading using crow bars or on tires will be allowed in any case.
Rubber belt may be used instead of crow bars or chains.
 Pipes should be loaded at the works for transportation, either by rail or by road, in such a
way that they are secure and that no movement can take place on the vehicle during transit.
The same care is needed if pipes are to be transferred from one vehicle to another,
however, short the journey may be.
 Un-loading of pipes should be carried out by means of chain block with shear legs or crane
of adequate capacity, using properly designed slings and spreader beams or specially
designed lifting beams. Slings should be placed around the circumference of the pipe and
should not be threaded through the pipe bore' as the latter method may damage the jointing
surfaces. For the same reasons, hooks located in the ends of the pipes should not be used.
859
damages to pipes.
 Pipes may be placed directly on the ground provided it is reasonably level and free from rocks
and other projections.
 Stacking in tiers is permissible provided timber bearers are placed between succeeding tiers.
 Rolling down of the stacked pipes must be avoided by providing wedges wherever required.
 All pipes shall be loaded /unloaded on/from truck by mechanical crane only. No hook shall
be used and nylon tape of sufficient size and width shall be used.
 Valves
various location.
 Air Valve :
firstly, in the waterfilled stage of the pipeline, filled with water by a certain velocity, the air
valve can discharge the remained gas in the pipe; secondly, at the normal working stage, the
air valve can discharge the small amount of gas gathered in the pipe timely; finally, during the
pump failure or maintenance stages, the air valve will replenish the gas into the pipe to break
the vacuum. According to the orifice size, displacement and work pressure, air valve is
divided into high pressure trace exhaust valve, low pressure air release valve and combined
air valve.
 Scour Valve :
These Valves are generally provided to drain out the pipe line. The exact location of Scour
pipeline crosses a stream or drainage structures, there will usually be a low point in the line
but if the main pipeline goes under the stream or drain, it cannot be completely drained into
the channel. In such a situation it is better to locate a scour connection at the lowest point that
will drain by gravity and provide for pumping out the part below the drain pipeline.
 Control Valve :
A control valve is a valve used to control fluid flow by varying the size of the flow passage as
directed by a signal from a controller. This enables the direct control of flow rate and the
consequential control of process quantities such as pressure, temperature, and liquid level.
I. Sliding Stem
 Globe valve
II. Rotary
 Butterfly valve
 Ball valve
III. Other
 Pinch valve
 Diaphragm valve
860
given in forgoing para No.6.0

Work of PDN shall be inspected, tested and certified by PMC / TPI / QC. Modalities of PMC
Laboratories)
3 S.G.S, Mumbai
5 VJTI, Mumbai
(i) All materials before being utilized in works shall be inspected and tested, by the Engineer In-
charge or his representative/QC. The nature of testing and periodical intervals at which such
testing is to be done etc. shall be as per the latest editions of relevant IS Codes and determined
by the Engineer In-charge. The day-to-day and periodical tests to be carried out on materials
mixes and placed concrete, mortar etc. shall be specified by the Engineer In-charge from time
to time and the Contractor shall provide free of cost all facilities towards collections of
samples etc. unless otherwise specified. Labours for collecting samples and transportation of
the samples to quality control authorities for test shall be provided free of cost by the
contractor. Also electricity, fuel, water curing tank and stores etc shall be provided free of
cost by the contractors.
(j) The materials shall be tested in QC laboratory or at any other place directed by the Engineer
In-charge. The Contractor shall obtain the test results from the concern authority and the
results given by such authorities shall be considered to determine whether all materials,
workmanship are of respective standard described in contract and in accordance with the
instructions of the Engineer In-charge. The Contractor’s representatives shall, however, be
given access to all operations and tests that may be carried out as aforesaid so that he may
satisfy himself regarding the procedure and methods adopted. It shall then be the Contractor’s
responsibility to produce on the work, materials and finished item to the standard as
determined by the laboratory tests or to take follow up action to rectify the quality.
861
(k) Testing charges for testing of Cement, TMT bars, all types of pipes and specials including
(l) The Contractor shall make suitable arrangements to see that one of his representatives
Contractor, fails to keep his representative present at site at the time of taking samples or fail
to provide required labours and other equipment to collect the samples, the same shall be
taken by the Engineer In-charge, and the samples selected shall be considered as authentic.
The cost incurred by the Engineer-In-charge when the Contractor fails to provide required
men and materials for collecting samples and or their transport shall be recovered from the
Contractor.

 On award of contract, the Contractor will have to provide adequate quality assurance setup
including Quality Assurance Engineer backed with suitable laboratory assistants, lab ours and
well equipped laboratory for taking necessary field test required as per specifications and as
per instructions of Engineer in charge.
 Following minimum persons shall be employed by the contractor at work site for Quality
Assurance.

2 Laboratory Assistants (Twelfth Pass with Two to Four

(One for each L.A.)
 Following minimum equipments shall be available in the field laboratory


for Sand & Metal.


862
carried out at the laboratory, selected by the Engineer-in-Charge at contractors cost .
The other tests of mortar, concrete, sand, coarse shall be carried out in field laboratory
setup by the contractor in presence of quality control representative at contractors
 The materials, mixes and any other arrangements, including lab ours, shall be supplied
specification.
work.

 The Manufacturing of pipes and specials for PCCP pipes shall be as per IS 784.
representative of Engineer-In-charge /WRD/QC/TPI. like
1. Steel Cylinder Test.
2. Dimensions - Length, Internal diameter, Core thickness, straightness and
finish.
3. Hydrostatic Factory Test
4. Permeability Test on Coating
5. Mortar soundness test
 While transporting pipes the vehicle shall have side supports approximately spaced
2m apart, and the pipes shall be secured effectively during the transportation. All posts
shall be flat with no sharp edges.
 A pipe section must be rolled or otherwise moved, such operation shall be done
863
 All pipes shall be loaded in trucks by mechanical crane/ tripod and unloaded carefully
using crane/ tripod. No unloading using crow bars or on tires will be allowed in any
case. Rubber belt may be used instead of crow bars or chains.
 Pipes should be loaded at the works for transportation, either by rail or by road, in
such a way that they are secure and that no movement can take place on the vehicle
during transit. The same care is needed if pipes are to be transferred from one vehicle
to another, however, short the journey may be.
 Un-loading of pipes should be carried out by means of chain block with shear legs or
crane of adequate capacity, using properly designed slings and spreader beams or
specially designed lifting beams. Slings should be placed around the circumference of
the pipe and should not be threaded through the pipe bore' as the latter method may
damage the jointing surfaces. For the same reasons, hooks located in the ends of the
pipes should not be used.
 Pipes may be placed directly on the ground provided it is reasonably level and free
 Stacking in tiers is permissible provided timber bearers are placed between succeeding
tiers.
 Rolling down of the stacked pipes must be avoided by providing wedges wherever
required.
 All pipes shall be loaded /unloaded on/from truck by mechanical crane only. No hook
shall be used and nylon tape of sufficient size and width shall be used.

Measurement
 The net length of pipes as laid or fixed shall be measured in running meters correct to
864
Payment
A. 80% of the payment will be released after supplying, lowering, laying, jointing
B. Balance 10% of the payment will be released after satisfactory hydraulic testing
of pipeline and backfilling of trenches.
C. Remaining 10% amount will be withheld and it will be released after successful
maintenance and operation for a period of five years after commissioning of
work of respective WUAs.

----------***----------
865
12.45 Lowering, Laying and Jointing in proper grade and alignment Pre-stressed
Concrete Cylinder Pipes (Item No. LIPDN 54)
Lowering, Laying and Jointing in proper grade and alignment Pre-stressed Concrete Cylinder
Pipes (PCCP) with welding & mortor coating joints including cost of conveyance from stores
to site of works, loading, unloading, hoisting, all labour involved, etc. complete but excluding
cost of rubber rings (For all class of pipes)

testing at works and site of alignment Pre-stressed Concrete Cylinder Pipes (PCCP) with
welding & mortor coating joints including cost of conveyance from stores to site of works,
loading, unloading, hoisting, all labour involved, etc. complete but excluding cost of rubber
rings (For all class of pipes)

clearing site and/or excavation shall rest with the Engineer In-charge. Useful material shall be
stacked as directed. The Contractor shall dispose off all un-useful materials as directed by the
Engineer In-charge.
 Demarcation
All materials such as pegs, bamboo’s and strings and templets for marking out slopes, and
labour required for line out should be provided by the Contractor at his own cost. The center
fixing reference stone at suitable distances on either side of the center line, beyond the canal
edges so that they are not disturbed during the construction period. The position of these
stones will be marked on the cross section.

(a)Benchmarks fixed by the Survey of India and temporary benchmarks established by the
Engineer In-charge in vicinity of PDN work will serve as control points for these works. The
Contractor shall establish sufficient number of reference benchmarks for facilitating setting
out of work and taking levels for the purpose of measurements.
(b)Before starting any work, the Contractor shall erect reference benchmarks, reference lines
and check profiles at convenient locations approved by the Engineer In-Charge. The
benchmark concrete block shall be 200mm x200mm x600mm with 400mm embedded in the
866
firm ground and 200 mm projecting above ground. The word ‘BM’ showing value of R.L. in
‘m’ shall be conspicuously carved and painted on the benchmark.
(c)The check profile shall be located 30m apart or closer as directed by the Engineer In-Charge
so as to ensure execution of all slopes, steps and elevations to the profile or profiles indicated
in the approved drawings. All important levels and all control points with respect to
benchmarks and reference lines shall be fixed and correlated by the Contractor. The
Contractor is fully responsible for maintaining all setting out work & Benchmark established
by Engineer-In-charge.
(d)All materials, labour and equipments (theodolites, levels, distometre, etc.) for setting out
works including construction of benchmarks in concrete, reference lines, check profiles and
surveys as may be required at the various stages of construction shall be supplied by the
Contractor this cost. For this following numbers of minimum equipments shall be provided
and maintained in good working condition by the Contractor.
2. Theodolite (Accuracy 1 second) 1No.
3. Levels 2Nos.
4. Staves 4Nos.
All equipments shall be of standard and approved make and precision, and shall be made
available in advance of starting of the work. All equipment shall be maintained, repaired
and got tested and certified as and when required for its accuracy from the standard test
houses or from the manufactures and to the satisfaction of the Engineer-In-Charge.

drawing or as directed by Engineer In -charge. Contractor must assume all
materials to be excavated and the difficulties of making and maintaining the required
excavation. The trench width at bottom shall be 300 mm more than 1.5 times outside
pipe diameter. In any case trench width shall not be less than 500 mm.
Engineer In-charge. Un-useful material from excavation shall be deposited in spoils as
and where directed by Engineer-In-charge.
 Surface or sub-soil water met with during trench excavation (PDN) and structure
867
material excavated under water level condition which requires intermediate stacking
for drying shall have to be rehandled. No extra payment for efforts for drying out of
soil, re-handling of dry soil, etc. shall be given. No payment for extra efforts for
excavation under this condition shall be made.
additional excavation as may be directed by the Engineer-In-charge, shall be rectified
at the cost of the Contractor. Filling and compaction for such over excavation using
the material as directed by the Engineer In- Charge shall also be at the cost of the
Contractor.
structure shall be over excavated to the extent as directed by the Engineer In Charge
and such over excavated section shall be filled with
suitable murum type soil to be placed in uniformly compacted layers as directed by
the Engineer In Charge. The over excavation made in such strata, filling by suitable
soil, and watering and compacting such soil will be paid separately under relevant
items. Above provision for over excavating and filling with suitable murum type or
good soil available material shall be applicable in case such treatment is found
essential.
 Laying of Pipes
 While laying of PCCP pipe, all precaution as mentioned in IS 783 shall be taken.
Concrete pipes have to be properly handled, bedded & back filled, if they have to
be provided.
 Jointing of pipes shall be done as per procedure mentioned in IS 783. The sections of
the pipe should be jointed together in such a manner that there shall be as little
868
 Jointing process of PCCP pipe consist of following steps.
 Aligning of pipes at joint locations.
 The basic requirements for all joints are as enumerated below.

c) cleanliness of all parts, particularly joint surface;
d) correct location of components;
e) centralization of spigot within socket;
f) provision of the correct gap between the end of the spigot and the back
of the socket
 The backfill material shall be placed to the line and grades as shown on drawings
or as prescribed in this paragraph or as directed by the Engineer-in-Charge.
more than 15cm thickness, with the first layer watered and compacted by
stamping or by mechanical means. The backfill shall be brought up as uniformly
as practicable on both sides of pipe to prevent unequal loading.
 Only soft earth and gravel of good quality free from boulder, roots, vegetable
matters etc. shall be used for refilling of trench upto 300mm above the top of the
pipe. If sufficient quantity of suitable (Sharp edge stone free) excavated earth is
not available, the trench shall be filled by borrowed gravel material upto 300 mm
 When compacting the soil against steep rock, abutment walls of concrete
structures, rollers shall not be used close to structures as structural damage is very
likely more particularly when structures have not been fully cured. The size and
weight of equipment will depend on nature of material, the height and load
assumed in design of structure. The backfill close to the structure up to the rolled
layer shall be compacted in suitable uniform layers, using pneumatic / hand
tampers as appropriate for dry density at average bulk density (+/- 10%). The
moisture content of the earth fill placed against the rock or the structure shall be
on higher/lower side of OMC by about 2% or so, to allow it to be compacted.
Profuse watering shall be done to pervious materials (sand) before compaction as
per instruction of the Engineer-in-Charge. Compaction at junction of earthwork
and backfill around the structure shall be carried out with special care.
869
farmers.
 The marking shall be constructed in prefabricated concrete block of size (15x15x45)
CM embedded in concrete block of size (30x30x30)CM. The base of this block
shall be buried in ground projecting only 15cm above the ground and the base
concrete block.
 These blocks shall be able to locate the pipeline as and where it is laid all over the
 The contractor shall show all this blocks jointly to the Engineer-in-charge or his
 Contractor shall maintained these blocks in proper order during operation
&maintenance period of the contract. Any damage done to these blocks for the
 The contractor shall submit the location of such blocks with specific identification
 The map of marking of the block shall be handed over to WUA while handing over
the command area.
 The Geotagging map showing Latitude and Longitude Value of each apex of laid
 The contract shall fix information boards of 1.2 m x 0.9 m size at various location as

charge.
2R.I.T.E.S. (Rail India Technical Economics Services)Mumbai
3S.G.S, Mumbai
4Vishveshvaraya National Institute of Technology, Nagpur
5VJTI, Mumbai
6CWPRS(Central Water & Power Research Station), Pune
870

Quality Assurance.
871

2 Laboratory Assistants (Twelth Pass with Two to Four

(One for each L.A.)


for Sand & Metal.


specifications or other wise required by the Engineer-in-Charge, the same shall be
carried out at the laboratory, selected by the Engineer-in-Charge at contractors cost .
The other tests of mortar, concrete, sand, coarse shall be carried out infield laboratory
setup by the contractor in presence of quality control representative at contractors
representative shall have a free access in these laboratories, to get himself at is field
872
specification.
work.

 All materials such as pegs, bamboo’s and strings and templates for marking out
slopes, and labour required for lineout should be provided by the Contractor at his
own cost.
used in back filling. If such usable material is in excess of the requirement of back
filling, the same shall be deposited in the spoils as and where directed by the
Engineer In-charge.
873
 While laying of PCCP pipe, all precaution as mentioned in IS 783 shall be taken
drawings.
 .Concrete pipes have to be properly handled, bedded & back filled, if they have to
be provided.
 Jointing of pipes shall be done as per procedure mentioned in IS 783. The sections of
the pipe should be jointed together in such a manner that there shall be as little
 Jointing process of PCCP pipe consist of following steps.
 Aligning of pipes at joint locations.
 The basic requirements for all joints are as enumerated below.

a) cleanliness of all parts, particularly joint surface;
b) correct location of components;
c) centralization of spigot within socket;
d) provision of the correct gap between the end of the spigot and the back
of the socket
874
of the farmers.

 Measurement
The net length of lowering, laying & jointing of pipes as laid or fixed shall be
measured in running meters correct to a cm. Specials shall be excluded and measured
in running meters or numbers as specified by Engineer-in-charge and paid for
separately under the relevant item. The portion of the pipe overlapped at the joints
shall not be included in the length of pipe work. Excavation, refilling, anchor blocks,
thrust blocks wherever required shall be measured and paid for separately under
relevant items of work.

 Payment
of respective WUAs.
875

----------***----------
876
12.46 Providing and supplying ISI standard specials & fitting suitable for P. C. C.
pipes (Item No. LIPDN 55)
Providing and supplying ISI standard specials & fitting suitable for P. C. C. pipes including
cost of labour, materials, and transportation to stores / site, loading and unloading
excluding GST levied by GOI & GOM in all respect, complete.

This specification covers the requirements for providing and supplying P. C. C. pipes
fitting / specials including loading, unloading, transportation upto departmental store,
stacking excluding GST levied by GOI & GOM in all respect.

 Introduction
The Prestressed Concrete Cylinder Pipe (PCCP) comprises of a welded sheet steel
cylinder with steel socket and spigot rings welded to its ends, lined with concrete suitably
compacted and circumferentially prestressed to withstand internal pressure and external
design load. PCCP pipe is subsequently coated with cement mortar to protect the steel
cylinder and prestressing wires.
Contractor shall provide on-site training on PCCP pipe laying, jointing, testing and
maintenance etc., to the personnel authorized by Engineer-in-Charge. The contractor
should provide technical Manual on PCCP pipes including precautions to be taken during
The manufacturing, testing, supplying, laying, jointing and testing at work sites of PCCP
Specification conflict with the requirements of the standards/Codes, this Specification shall
govern. Others Codes not specifically mentioned here but pertaining to the use of PCCP
Pipes form part of these Specifications.

Part 1&2 Concrete.
Concrete
877
 Raw Materials
Raw materials used to manufacture PCCP Pipes are cement, aggregates, water, admixture,
steel reinforcement, steel for cylinders and specials.
 Cement
The cement used in the manufacture of PCCP pipes shall conform to one of the following.
1) 43/53 grade Ordinary Portland Cement conforming to IS:8112/IS 12269

2) Rapid Hardening Portland cement conforming to IS: 8041
3) Portland Slag cement (with not more than 50% slag) conforming to IS: 455
4) Sulphate resisting Portland Cement conforming to IS: 12330
 Aggregate
 Water
 Admixtures
conform to IS 9103.
 Steel reinforcement
 Prestressing steel wire shall conform to IS 1785.
 Un tensioned reinforcement may consist of MS bars conforming to IS432
or HYSD bar conforming to 1786.
 Steel plates for Cylinders, Joint rings and Specials

Steel plates for cylinders, joint rings and Specials shall conform to IS: 2062

The Manufacturing of pipes and specials for PCCP pipes shall be as per IS 784. The
mould and method of manufacture of pipe shall be such that the form and dimensions of
the finished pipe conform to IS 784 and the surface and edges of the pipes are clean and
true. Various steps involved in pipe manufacturing process are as given below.
 Fabrication & hydrostatic testing of steel cylinder as per required size

 Welding of steel socket and spigot rings to end of steel cylinder.
878
method ( Minimum cement content - 350kg/m3, Maximum W/C ratio - 0.5 and
Minimum compressive strength at 28 days, - 40 N/mm2)
 Rich cement mortar out coating (Cover coating) on pipe. (minimum cement
content- 540kg/m3 , minimum water cement ratio – 0.27, minimum compressive
strength of cement mortar at 28 days-35 N/mm2).
 Curing of pipe.
Cross-section of PCCP Pipe Joint
PCCP pipe shall be designed to withstand the combined effects of internal water pressure &
external loads. Design of PCCP pipes shall be site specific as internal water pressure will
 Valves
 Air Valve :
 Scour Valve :
These Valves are generally provided to drain out the pipe line. The exact location of
879
 Control Valve :
A) Sliding Stem
 Globe valve
B) Rotary
 Butterfly valve
 Ball valve
C) Other
 Pinch valve
 Diaphragm valve

Work of PDN shall be inspected, tested and certified by PMC / TPI / QC. Modalities
charge.
3 S.G.S, Mumbai
5 VJTI, Mumbai
880

Quality Assurance.
881

2 Laboratory Assistants(Twelth Pass with Two to Four

(One for each L.A.)

Set up by the contractor.

for Sand & Metal.


infield laboratory set up by the contractor in presence of quality control
quality of work.
 The materials, mixes and any other arrangements, including lab ours, shall be supplied
about procedures of test in etc. Even if the contractor or his representative fails to
882
specification.
work.

 Specials & Fittings shall be suitable for fixing PCCP pipeline and shall conform to the
requirements of IS: 784 and IS: 7322.
 Specials and fittings for PCCP pipes shall be made out of steel plate fabricated to the
required dimensions.
 The steel for fabricated steel plate specials, is cut, shaped and welded so that finished
special has the required shape and internal dimensions.
 Adjacent segments are joined by means of lap or buttwelding.
 The steel used for manufacturing of specials shall conform to IS: 2062 or with its
equivalent mechanical properties. The steel plate thickness for specials shall be as SP-
192Contractor No. of Correction Executive Engineer given in IS 7322.
 The specials shall be protected against corrosion by application of Cement mortar
lining / coating or anticorrosive Epoxy Coating. Before protective coating, the
welding of special shall be tested by use of hot oil or dye penetrate according to IS
3658 and defects if any shall be rectified. In die penetration test, a whitewash is
applied over the weld on one side of the Special on other side when colored paraffin
or similar product is applied over the weld, no colored spot shall appear on the white
wash before 4 h. if any colored spots appear before 4 h. weld shall be repaired and
retested.
 In case of lining & coating with Cement mortar, the following procedure shall be
applicable. The specials shall be lined inside and outside with 25 mm thick cement
mortar, reinforced with 50X50 mm weld mesh of specified gauge.
 The cement mortar inside shall be 1:1.5 (1 part cement: 1.5 part sand) and cement
mortar out side shall be 1:2 (1 part cement: 2 part sand).
 In case of Anticorrosive Epoxy coating for the interior and exterior of the Specials
and fittings following procedure shall be applicable.
 Before application of epoxy, the surfaces shall thoroughly be cleaned to remove oil,
grease, or other foreign material. The minimum dry film thickness (DFT) shall be at
least 406 μm.
 As part of the pipeline test, all the specials and fittings shall be tested for hydrostatic
pressure as specified for PCCP pipeline and to the pressure specified for pipes in the
reaches where the specials are fitted. The contractor is fully responsible for any
defects in manufacturing of Specials or fittings not conforming to IS Specifications.
 Extreme care shall be taken while carting the specials to site, so that protective coating
is not damaged.
 To assure the desired quality of work. Whenever the testing of construction materials,
883
Engineer-in-Charge at contractors cost . The other tests of mortar, concrete, sand,
coarse shall be carried out infield laboratory setup by the contractor in presence of

Measurement
The specials of pipes as laid or fixed shall be measured in Kilogram correct to a one gram
as specified by Engineer-in-charge and paid for separately under the relevant item. The
portion of the pipe overlapped at the joints shall not be included in the length of pipe work.
Excavation, refilling, anchor blocks, thrust blocks wherever required shall be measured and
paid for separately under relevant items of work.

Payment
I. 80% of the payment will be released after supplying, lowering, laying, jointing
II. Balance 10% of the payment will be released after satisfactory hydraulic testing of
III. Remaining 10% amount will be withheld and it will be released after successful
of respective WUAs.


----------***----------
884
12.47 Hydraulic testing of Pre-stressed Concrete Cylinder Pipes with rubber ring
(Item No. LIPDN 56)
12. 47.1 Description of Item

Hydraulic testing of Pre-stressed Concrete Cylinder Pipes with rubber ring joints to specified
pressure including cost of all materials and labour and water for testing for the length up to 1
km., using reciprocating type pumps which should be able to provide specified test pressure
gauges and other necessary equipments, labour, operation charges, etc. required for testing.
The rate under this item shall also include cost of retesting, if necessary.
12. 47.2 Scope of work.
This specification covers the requirements for hydraulic testing at works and site of Pre-
stressed Concrete Cylinder Pipes. Pipe line shall be tested for site test pressure as per IS 783
& IS 784 for ensuring quality of manufacture as per procedure specified in IS 783.
12. 47.3 Material Specifications
Field Testing of Pipeline system

 AS per I.S.784, the test pressure should be 1.5 times design working pressure.
 Test procedure: Each section should be properly sealed off, preferably with special stop
secured by adequate anchors. The thrust on the stop ends should be calculated on the full
provide .a concrete anchor block of couple of pipes laid and earth tamped around which has
subsequently to be demolished rather than risk movement of the stop ends during testing.
Hydraulic jacks may be inserted between the temporary anchors and stop ends in order to
take up any horizontal movement of the temporary anchor. All permanent anchors should
be in position and, if of concrete, should have developed adequate strength before testing
begins. The section under test should be filled with water, taking care that all air is
displaced either through vents at the high points, or by using a swab.
After filling, the pipeline should be left under operating pressure for a period in order to
upon many factors such as initial permeability, absorption, movement of the pipeline under
pressure and the quantity of air trapped.
More water should be pumped in from a calibrated container until the required test pressure
is reached. The test pressure should be maintained throughout the test by means of
regular intervals. The generally accepted standard for absorbent pipelines such as PSC pipes
is 3 liter per millimeter of pipe diameter per kilometer of pipeline per day for each 30 meter
head-of pressure applied.
885
 Leak Detection -If the test is not satisfactory, the fault should be found and rectified.
Where there is difficulty in locating a fault, the section under test should be subdivided and
If any leakage is found during testing of pipeline, Contractor will have to attend the same
immediately and rectify at his cost within. If Contractor fails to rectify the defect, the entire
length of pipeline between two adjacent outlets shall be rejected. If any intermediate
payment is made to the Contractor for portion under rejection, the same shall be recovered
from the outstanding dues of the Contractor.
 Final Testing –After all sections have been jointed together on completion of section
testing, a test on the complete pipeline should be carried out. This test should be carried out
at a pressure not less than the working pressure of the pipeline, care being taken to ensure
that the pressure at the lowest point in the pipeline does not exceed the maximum. During
the test, an inspection should be made of all work which has not been subjected to sectional
tests.

Work of PDN shall be inspected, tested and certified by PMC / TPI / QC. Modalities of
Laboratories)
3 S.G.S, Mumbai
5 VJTI, Mumbai
shall be specified by the Engineer In-charge from time to time and the Contractor shall
provide free of cost all facilities towards collections of samples etc. unless otherwise
specified. Labours for collecting samples and transportation of the samples to quality
control authorities for test shall be provided free of cost by the contractor. Also
886
electricity, fuel, water curing tank and stores etc shall be provided free of cost by the
contractors.
Quality Assurance.


(One for each L.A.)

887

for Sand & Metal.

 It is the responsibility of the contractor to assure the desired quality of work. Whenever
mortar, concrete, sand, coarse aggregates etc. shall be carried out in field laboratory setup
by the contractor in presence of quality control representative at contractors cost.
 The materials, mixes and any other arrangements, including labours, shall be supplied by
the contractor. The samples for testing shall be taken in the presence of Engineer-in-
Charge or his representative /QC present on site. The contractor or his authorized
representative shall have a free access in these laboratories, to get himself satisfied about
procedures of testing etc. Even if the contractor or his representative fails to remain
present while collecting samples or testing, the results will be considered as authentic and
binding on the contractor.
Charge along with proofs in support of quality of material brought for the work, the
process/ execution of work is as per specification.
work.

selected test pressure and maintaining this for a sufficient period to allow for absorption
of water by the pipe material.
 AS per I.S.784, the test pressure should be 1.5 times design working pressure.
 Each section should be properly sealed off, preferably with special stop secured by
adequate anchors. The thrust on the stop ends should be calculated on the full socket
internal diameter and the anchors designed to resist it. It may often be economical to
provide. a concrete anchor block of couple of pipes laid and earth tamped around which
888
has subsequently to be demolished rather than risk movement of the stop ends during
testing.
 Hydraulic jacks may be inserted between the temporary anchors and stop ends in order to
take up any horizontal movement of the temporary anchor. All permanent anchors should
be in position and, if of concrete, should have developed adequate strength before testing
begins.
 The section under test should be filled with water, taking care that all air is displaced
either through vents at the high points, or by using a swab.
 After filling, the pipeline should be left under operating pressure for a period in order to
upon many factors such as initial permeability, absorption, movement of the pipeline
under pressure and the quantity of air trapped.
 More water should be pumped in from a calibrated container until the required test
pressure is reached. The test pressure should be maintained throughout the test by means
of continuous pumping. The rate of loss of water from the container should be
determined at regular intervals. The generally accepted standard for absorbent pipelines
such as PSC pipes is 3 liter per millimeter of pipe diameter per kilometer of pipeline per
day for each 30 meter head-of pressure applied.
 Leak Detection -If the test is not satisfactory, the fault should be found and rectified.
Where there is difficulty in locating a fault, the section under test should be subdivided
and each part tested separately.
same immediately and rectify at his cost within. If Contractor fails to rectify the defect,
the entire length of pipeline between two adjacent outlets shall be rejected. If any
 Final Testing –After all sections have been jointed together on completion of section
testing, a test on the complete pipeline should be carried out. This test should be carried
out at a pressure not less than the working pressure of the pipeline, care being taken to
ensure that the pressure at the lowest point in the pipeline does not exceed the maximum.
During the test, an inspection should be made of all work which has not been subjected
to sectional tests.
 Third Party Inspection of PDN work shall be inspected, tested and certified by

Measurement
The Hydraulic testing of pipes as laid or fixed shall be measured in Kilometer correct to
one metre. Specials shall be excluded and measured in Kilogram or numbers as specified
by Engineer-in-charge and paid for separately under the relevant item. The portion of the
pipe overlapped at the joints shall not be included in the length of pipe work. Excavation,

 Payment
889
of respective WUAs.
a) After Successful Operation and Maintenance for First year-2%

b) After Successful Operation and Maintenance for Second year-2%
c) After Successful Operation and Maintenance for Third year-2%
d) After Successful Operation and Maintenance for Fourth year-2%
e) After Successful Operation and Maintenance for Fifth year-2%
--------***----------
Note
 The contractor shall operate and maintain the complete pipe distribution network
for the period of 5 (five) years after commissioning. Out of this period, during last
two years the operation of the schemes shall be done by the contractor jointly along
with WUA. On completion of O & M period, the system shall be handed over to
WUA
 During rotation period, once in every year, the Contractor shall perform
hydraulic test to the satisfaction of Engineer In-charge to verify the flow of
designed discharge, detect or confirm any leakage in the system and rectify at his
own cost. The testing shall preferably be conducted jointly with members of
WUA/representative of Engineer In-charge, technical representative of contractor
and any other stake holder.
 On completion of every Irrigation season, the contractor shall flush the pipe line
from its tail flush valve so that any siltation, vegetation or obstruction is cleaned
and pipe is able to flow designed discharge for next season.
 During the O & M period, contractor shall give training to the members of WUA
about O & M of PDN work and its efficient use and protection of the system from
any damages.
 The contractor shall prepare a detail map of the permanent marking along the
alignment of pipe and submit the same to Engineer In-charge. The Engineer In-
charge shall verify and endorse the location of the marking and handover these
signed maps as a permanent record to WUA. Along with this, the detailed
Geotagged map of laid pipeline shall also be handed over to WUA.
 In association of the members of WUA, the Engineer In-charge shall confirm the
release of designed discharge through every outlet before handing over. In case of
any short fall or defect, it should be made good from the contractor at his own cost.
890
Specification For Single door CI D/F NRV OF Size 100 to 600 mm
12.48 Providing, erecting & testing of approved make CI D/F reflux valves (Item
No. LIPDN 57)
Providing, erecting & testing of approved make CI D/F reflux valves (non-return valves) of
proposed diameter with technical specifications as below
i. Design, manufacturing & testing as per standard IS 5312 Part 1 Including transportation,
inspection, unloading, loading, stacking excluding GST levied by GOI & GOM in all respect
etc. complete. Reflux valves as per I.S.5312 Part I (1986)

This specification covers the requirements for providing, erection & testing of Non return
Valves of cast iron of following class and diameters confirming to the I.S. specification
inclusive cost of jointing materials (fasteners, Neoprene Rubber gasket etc.) excluding GST
levied by GOI & GOM in all respect including Third party inspection charges of TPI Agency
completed as directed by Engineer-in-charge (IS 5312- Part 1)
Sr. No. Component Material & IS codes

1 Body, Door, Cover, hinges, door bearing IS 210 FG 200
holder
2 Hinge pins,door pins, suspension pins Stainless steel IS 6603 Gr.12Cr12
3 Disc face ring, Body seat rings, bearing leaded in Bronze IS 318 GR LTB2
bushes, plugs for hinge pin
4 Nut bolts Carbon steel IS 1363
5 Bolts and nuts Stainless Steel / Carbon Steel
6 Gaskets Rubber IS 638 Type B
7 Flanges IS 1538
891
• Classification of valves –
These valves are classified on the basis of nominal pressure (PN) defined as maximum gauge
working pressure (MPa).
PN1.0 - Maximum gauge working pressure- 1.0 MPa
• Typical drawing of single door reflux valve
• Sizes of By-Pass arrangement
Size of
valves in 50 65 80 100 125 150 200 250 300 350 400 450 500 600
mm
By pass
arrangement
10 10 10 10 15 15 25 25 40 40 40 50 50 65
minimum
size in mm
• Testing
Non return Valve shall be subjected to hydrostatic testing of body & seat. The test duration
test pressure shall be as below. The test conditions will be as per IS 5312(Part 1)-2004. The
test shall be witnessed by Engineer In-Charge or his representative. The material test reports
of body, cover, door & pins should be submitted by manufacturer & same should be reviewed
by Engineer in-Charge.
892
Sr. No PN rating Test for Test pressure Test Duration
MPa In minutes
Body 1.5 5
1 PN 1.0
Seat 1 2
Body 2.4 5
2 PN 1.6
Seat 1.6 2
• Coating –
All coatings shall be carried out after satisfactory testing of the valves prior to dispatch. All
exposed machined ferrous surfaces shall be painted with one coat of aluminum red oxide
primer. Two coats of black Japan conforming to type B of IS 341 or paint conforming to IS
9862 or IS 2932 shall be applied by brush or spray for exterior application in colour as
approved by engineer In-charge.

● The net quantity of valves shall be measured on number basis
● Damages during transit, handling, storage will be to the Contractor’s account and
replacement for such valves has to be made by the Contractor without any extra cost as

The break up to payment for supplying, erection & testing of valve shall be as under:-
A) 80% of the payment will be released after supply of valves

B) Balance 10% of the payment will be released after erection of valves
C) Balance 10% of the payment will be released after testing & commissioning of valves
893
Sample Quality Assurance Plan (QAP may be modified as per directions of Engineer In-charge)
FORMAT
SR. COMPONENT TYPE OF QUANTUM REFERENCE INSPECTION
CHARACTERISTICS ACCEPTANCE NORM OF REMARKS
NO & OPRATION CHECK OF CHECK DOCUMENT
RECORD
RAW CLIEN
A Manufacturer
MATERIAL T
INSP.
VISUAL CHECK VISUAL 100% P -
REPORT
APPROVED GA
APPROVED GA
MECHANICAL MECHANI 1 TEST DRG./REL
CASTING: DRG./REL MATERIAL MTC P R
PROPERTIES CAL TEST BAR/HEAT MATERIAL
BODY, DOOR SPEC.
SPEC.
& COVER
APPROVED GA
APPROVED GA
CHEMICAL CHEMICA 1 TEST DRG./REL
DRG./REL MATERIAL MTC P R
PROPERTIES L TEST BAR/HEAT MATERIAL
SPEC.
SPEC.
APPROVED GA
APPROVED GA
A.2 HINGE DRG./REL MATERIAL MTC P R
SPEC.
SPEC.
CHEMICA APPROVED GA
CHEMICAL & APPROVED GA
ROUND BAR: L& 1 TEST DRG./REL
A.3 MECHANICAL DRG./REL MATERIAL MTC P R
HINGE PIN MECHANI BAR/HEAT MATERIAL
PROPERTIES SPEC.
CAL TEST SPEC.
CHEMICA APPROVED GA
L& 1 TEST DRG./REL
A.4 FACE RING MECHANICAL DRG./REL MATERIAL MTC P R
MECHANI BAR/HEAT MATERIAL
PROPERTIES SPEC.
CAL TEST SPEC.
B INPROCESS INSPECTION
BODY,DOOR
& HINGE COMPONENT
B.1 SURFACE DEFECTS VISUAL 100% -- -- P
AFTER DRAWING
MACHINING
COMPONENT
DIMENSIONS VISUAL 100% -- -- P
HINGE PIN DRAWING
B.2
RING NO LINEAR TEST
SURFACE DEFECTS DP TEST 100% ASTM A-165 P R
INDICATION EPORT
BY PASS COMPONENT
B.3 DIMENSIONS VISUAL 100% -- -- P
VALVES DRAWING
894
C.0 FINAL INSPECTION
No Visually Detectable
100% By & 10% By APPROVED GA Leakage through the
COMPLETE BODY HYDRO TEST TEST REPORT P W
CLIENT/Agency DRAWING/REL shell [ Seepage on body
ASSEMBLED not allowed]
NON RETURN SEAT HYDRO LEAKAGE No Leakage Through
C.1 HYDRO TEST -- Do -- -- Do -- TEST REPORT P W
VALVE [ TEST Seat
BEFORE
PAINTING] No Visually permanent
01 No. of Each Size
Disc strength Test -- Do -- deformation. Leakage TEST REPORT P W
& Rating per project
permitted
COMPLETE
OVERALL
ASSEMBLED
DIMENSION
NON RETURN 100% By & 10% By APPROVED GA APPROVED GA DIMENSIONAL
C.2 Verification of MEASUREMENT/Visual P R
VALVE [ CLIENT/Agency DRAWING/Data sheet DRAWING/Data sheet REPORT
Heat no./Flow
BEFORE
direction
PAINTING ]
COMPLETE
PAINTING/Tag
ASSEMBLED PROCEDURE/Data PROCEDURE/Data COMPLINCE
C.3 marking/Name PAINTING/ visual 100% P R
NON RETURN sheet sheet CERTIFICATE
plate visual
VALVE
LEGEND : P : - PERFORM R : - REVIEW W : - WITNESS
895
Specification For Multidoor CI D/F NRV OF Size 700 to 1200 mm
12.49 Specification For Multidoor CI D/F NRV OF Size 700 to 1200 mm

( Item No. LIPDN 58 )
Providing, supplying & erecting of approved make multi door CI D/F reflux valves (non-
return valves ) of proposed diameter with technical specifications as below
Design, manufacturing & testing as per standard IS 5312 Part 2 Including transportation,
etc. complete. Reflux valves as per I.S.5312 Part II 2004

1 Body, Door, Cover, hinges, door bearing
IS 210 FG 200
holder
2 Hingepins,door pins, suspension pins Stainless steel IS 6603 Gr.12Cr12


7 Flanges IS 1538
896
• Typical drawing of multi door reflux
valve
897
Size of valves in mm 700 750 800 900 1000 1100 1200
By pass arrangement
100 100 100 100 100 100 100
minimum size in mm
• Testing
Non return valve shall be subjected to hydrostatic testing of body & seat. The test duration
MPa In minutes
Body 1.5 5
1 PN 1.0
Seat 1 2
Body 2.4 5
2 PN 1.6
Seat 1.6 2
• Coating –



898
11.0 Sample Quality Assurance Plan ( QAP may be modified as per directions of Engineer In-charge)
FORMAT
SR.N COMPONENT & TYPE OF QUANTUM REFERENCE ACCEPTANCE INSPECTION
CHARACTERISTICS OF REMARKS
O OPRATION CHECK OF CHECK DOCUMENT NORM
RECORD
RAW Manufacturer
A CLIENT
MATERIAL
INSP.
REPORT
APPROVED GA
APPROVED GA
CASTING: DRG./REL MTC P R
BODY, DOOR & MATERIAL SPEC.
SPEC.
COVER
APPROVED GA
APPROVED GA
DRG./REL MTC P R
MATERIAL SPEC.
SPEC.
APPROVED GA
APPROVED GA
A.2 HINGE DRG./REL MTC P R
MATERIAL SPEC.
SPEC.
CHEMICA APPROVED GA
A.3 MECHANICAL DRG./REL MTC P R
PROPERTIES MATERIAL SPEC.
CAL TEST SPEC.
CHEMICA APPROVED GA
L& 1 TEST DRG./REL
A.4 FACE RING MECHANICAL DRG./REL MTC P R
CAL TEST SPEC.
BODY,DOOR &
COMPONENT
B.1 HINGE AFTER SURFACE DEFECTS VISUAL 100% -- -- P
DRAWING
MACHINING
COMPONENT
HINGE PIN DRAWING
B.2
RING NO LINEAR TEST
INDICATION EPORT
BY PASS COMPONENT
VALVES DRAWING
899
No Visually
100% By & Detectable Leakage
APPROVED GA
COMPLETE BODY HYDRO TEST 10% By through the shell [ TEST REPORT P W
DRAWING/REL
ASSEMBLED CLIENT/Agency Seepage on body
NON not allowed]
C.1 RETURN HYDRO TEST SEAT HYDRO No Leakage
-- Do -- -- Do -- TEST REPORT P W
VALVE LEAKAGE TEST Through Seat
[ BEFORE No Visually
PAINTING ] 01 No. of Each
permanent
Disc strength Test Size & Rating -- Do -- TEST REPORT P W
deformation.
per project
Leakage permitted
COMPLETE
ASSEMBLED OVERALL
NON DIMENSION 100% By & APPROVED GA APPROVED GA
DIMENSIONAL
C.2 RETURN Verification of MEASUREMENT/Visual 10% By DRAWING/Data DRAWING/Data P R
REPORT
VALVE Heat no./Flow CLIENT/Agency sheet sheet
[ BEFORE direction
PAINTING ]
COMPLETE
ASSEMBLED PAINTING/Tag
COMPLINCE
C.3 NON marking/Name PAINTING/ visual 100% PROCEDURE/Data PROCEDURE/Data P R
CERTIFICATE
RETURN plate visual sheet sheet
VALVE
900
Specification For Single Door Ductile Iron D/F NRV Of Size 100 To 600 m
12.50 Specification For Single Door Ductile Iron D/F NRV Of Size 100 To 600
mm (Item No. LIPDN 59)

Providing, erecting & testing of approved make DI or SGI D/F reflux valves (non-return
valves ) of proposed diameter. with technical specifications as below
etc. complete. Reflux valves as per I.S.5312 Part I 2004


1 Body, Door, Cover, hinges, door bearing Ductile Iron IS 1865 Gr. 500/7
holder


7 Flanges IS 1538
901
Size of
valves in 50 65 80 100 125 150 200 250 300 350 400 450 500 600
mm
By pass
arrangement
10 10 10 10 15 15 25 25 40 40 40 50 50 65
minimum
size in mm
• Testing
Non return valve shall be subjected to hydrostatic testing of body & seat. The test duration
902
MPa In minutes
Body 1.5 5
1 PN 1.0
Seat 1 2
Body 2.4 5
2 PN 1.6
Seat 1.6 2
• Coating –



903
11.0 Sample Quality Assurance Plan (QAP may be modified as per directions of Engineer In-charge)
FORMAT
SR. COMPONENT & TYPE OF QUANTUM REFERENCE ACCEPTANCE INSPECTION
NO OPRATION CHECK OF CHECK DOCUMENT NORM
RECORD
Manufacturer
A RAW MATERIAL CLIENT
INSP.
REPORT
APPROVED APPROVED
MECHANICAL MECHANI 1 TEST GA DRG./REL GA DRG./REL
CASTING: MTC P R
PROPERTIES CAL TEST BAR/HEAT MATERIAL MATERIAL
BODY, DOOR &
SPEC. SPEC.
COVER
APPROVED APPROVED
CHEMICAL CHEMICA 1 TEST GA DRG./REL GA DRG./REL
MTC P R
PROPERTIES L TEST BAR/HEAT MATERIAL MATERIAL
SPEC. SPEC.
APPROVED APPROVED
MECHANICAL MECHANI 1 TEST GA DRG./REL GA DRG./REL
A.2 HINGE MTC P R
PROPERTIES CAL TEST BAR/HEAT MATERIAL MATERIAL
SPEC. SPEC.
CHEMICA APPROVED APPROVED
CHEMICAL &
ROUND BAR: L& 1 TEST GA DRG./REL GA DRG./REL
A.3 MECHANICAL MTC P R
HINGE PIN MECHANI BAR/HEAT MATERIAL MATERIAL
PROPERTIES
CAL TEST SPEC. SPEC.
CHEMICA APPROVED APPROVED
CHEMICAL &
L& 1 TEST GA DRG./REL GA DRG./REL
A.4 FACE RING MECHANICAL MTC P R
MECHANI BAR/HEAT MATERIAL MATERIAL
PROPERTIES
CAL TEST SPEC. SPEC.
BODY,DOOR &
COMPONEN
T DRAWING
MACHINING
COMPONENT
DRAWING
B.2 HINGE PIN RING
NO LINEAR TEST
INDICATION EPORT
BY PASS COMPONENT
VALVES DRAWING
904
No Visually
Detectable Leakage
100% By & 10% APPROVED GA
COMPLETE BODY HYDRO TEST through the shell [ TEST REPORT P W
By CLIENT/Agency DRAWING/REL
ASSEMBLED Seepage on body
NON not allowed]
PAINTING ] 01 No. of Each Size permanent
Disc strength Test -- Do -- TEST REPORT P W
& Rating per project deformation.
Leakage permitted
COMPLETE
ASSEMBLED OVERALL
NON DIMENSION APPROVED GA APPROVED GA
100% By & 10% DIMENSIONAL
C.2 RETURN Verification of MEASUREMENT/Visual DRAWING/Data DRAWING/Data P R
By CLIENT/Agency REPORT
VALVE Heat no./Flow sheet sheet
[ BEFORE direction
PAINTING ]
COMPLETE
PROCEDURE/Data COMPLINCE
C.3 NON marking/Name PAINTING/ visual 100% PROCEDURE/Data P R
sheet CERTIFICATE
RETURN plate visual sheet
VALVE
905
Specification For Multidoor Ductile iron D/F NRV OF Size 700 to 1200 mm
12.51 Specification For Multidoor Ductile iron D/F NRV OF Size 700 to 1200 mm
Providing, supplying & erecting of approved make multi door DI or SGI D/F reflux valves
(non-return valves ) of proposed diameter with technical specifications as below
etc. complete. Reflux valves as per I.S.5312 Part II (1986)

1 Body, Door, Cover, hinges, door bearing Ductile Iron IS 1865 Gr. 500/7
holder

7 Flanges IS 1538
906
907
Typical drawing of multi door reflux
VALVE
908
By pass arrangement
100 100 100 100 100 100 100
minimum size in mm
• Testing
Non Return valve shall be subjected to hydrostatic testing of body & seat. The test duration
MPa In minutes
Body 1.5 5
1 PN 1.0
Seat 1 2
Body 2.4 5
2 PN 1.6
Seat 1.6 2
• Coating –



909
FORMAT
RECORD
Manufacturer
INSP.
REPORT
APPROVED GA
APPROVED GA
SPEC.
COVER
APPROVED GA
APPROVED GA
DRG./REL MTC P R
MATERIAL SPEC.
SPEC.
APPROVED GA
APPROVED GA
MATERIAL SPEC.
SPEC.
CHEMICA APPROVED GA
CAL TEST SPEC.
CHEMICA APPROVED GA
L& 1 TEST DRG./REL
CAL TEST SPEC.
BODY,DOOR &
COMPONENT
DRAWING
MACHINING
COMPONENT
DRAWING
B.2 HINGE PIN RING
NO LINEAR TEST
INDICATION EPORT
COMPONENT
B.3 BY PASS VALVES DIMENSIONS VISUAL 100% -- -- P
DRAWING
910
No Visually
Detectable Leakage
100% By & 10% By APPROVED GA
COMPLETE BODY HYDRO TEST through the shell [ TEST REPORT P W
CLIENT/Agency DRAWING/REL
ASSEMBLED Seepage on body
NON not allowed]
PAINTING ] 01 No. of Each Size & permanent
Rating per project deformation.
Leakage permitted
COMPLETE
ASSEMBLED OVERALL
NON DIMENSION APPROVED GA APPROVED GA
100% By & 10% By DIMENSIONAL
C.2 RETURN Verification of MEASUREMENT/Visual DRAWING/Data DRAWING/Data P R
CLIENT/Agency REPORT
VALVE Heat no./Flow sheet sheet
[ BEFORE direction
PAINTING ]
COMPLETE
sheet CERTIFICATE
VALVE
911
Specification For Single Door Cast steel D/F NRV OF Size 100 to 600 mm
12.52 Specification For Single Door Cast steel D/F NRV OF Size 100 to 600 mm
Providing, erecting & testing of approved make cast steel D/F reflux valves (non-return
valves ) of proposed diameter. with technical specifications as below
etc. complete. Reflux valves as per I.S.5312 Part I 2004


1 Body, Door, Cover, hinges, door bearing Cast Steel 1030 GR230 – 450 W
holder
bushes, plugs for hinge oin


7 Flanges IS 1538
912
Size of
valves in 50 65 80 100 125 150 200 250 300 350 400 450 500 600
mm
By pass
arrangement
10 10 10 10 15 15 25 25 40 40 40 50 50 65
minimum
size in mm
• Testing
913
MPa In minutes
Body 1.5 5
1 PN 1.0
Seat 1 2
Body 2.4 5
2 PN 1.6
Seat 1.6 2
• Coating –



914
FORMAT
COMPONENT & TYPE OF QUANTUM REFERENCE ACCEPTANCE INSPECTION
SR.NO CHARACTERISTICS OF REMARKS
OPRATION CHECK OF CHECK DOCUMENT NORM
RECORD
Manufacturer
INSP.
REPORT
APPROVED GA
APPROVED GA
SPEC.
COVER
APPROVED GA
APPROVED GA
DRG./REL MTC P R
MATERIAL SPEC.
SPEC.
APPROVED GA
APPROVED GA
MATERIAL SPEC.
SPEC.
CHEMICA APPROVED GA
CAL TEST SPEC.
CHEMICA APPROVED GA
L& 1 TEST DRG./REL
CAL TEST SPEC.
BODY,DOOR &
COMPONENT
DRAWING
MACHINING
COMPONENT
HINGE PIN DRAWING
B.2
RING NO LINEAR TEST
INDICATION EPORT
BY PASS COMPONENT
VALVES DRAWING
915
COMPLETE 100% By & 10% By APPROVED GA Leakage through the
BODY HYDRO TEST TEST REPORT P W
ASSEMBLED CLIENT/Agency DRAWING/REL shell [ Seepage on body
NON not allowed]
C.1 RETURN HYDRO TEST SEAT HYDRO No Leakage Through
VALVE LEAKAGE TEST Seat
[ BEFORE No Visually permanent
PAINTING ] 01 No. of Each Size
permitted
COMPLETE
ASSEMBLED OVERALL
NON DIMENSION APPROVED GA
100% By & 10% By APPROVED GA DIMENSIONAL
C.2 RETURN Verification of MEASUREMENT/Visual DRAWING/Data P R
CLIENT/Agency DRAWING/Data sheet REPORT
VALVE Heat no./Flow sheet
[ BEFORE direction
PAINTING ]
COMPLETE
sheet CERTIFICATE
VALVE
916
Specification For Multidoor Cast steel D/F NRV OF Size 700 to 1200 mm
12.53 SPECIFICATION FOR Multidoor Cast steel D/F NRV OF Size 700 to 1200
mm (Item No. LIPDN 62)

Providing, supplying & erecting of approved make multi door cast steel D/F reflux valves
(non-return valves) of proposed diameter with technical specifications as below:
etc. complete. Reflux valves as per I.S.5312 Part II (1986)

1 Body, Door, Cover, hinges, door bearing Cast steel 1030 GR 230-450W
holder


7 Flanges IS 1538
917
918
Typical drawing of multi door reflux
valve
919
By pass arrangement
100 100 100 100 100 100 100
minimum size in mm
• Testing
MPa In minutes
Body 1.5 5
1 PN 1.0
Seat 1 2
Body 2.4 5
2 PN 1.6
Seat 1.6 2
• Coating –


920
11.0 Sample Quality Assurance Plan (QAP may be modified as per directions of Engineer In-Charge)
FORMAT
RECORD
RAW Manufacturer
A CLIENT
MATERIAL
INSP.
REPORT
APPROVED GA
APPROVED GA
SPEC.
COVER
APPROVED GA
APPROVED GA
DRG./REL MTC P R
MATERIAL SPEC.
SPEC.
APPROVED GA
APPROVED GA
MATERIAL SPEC.
SPEC.
CHEMICA APPROVED GA
CAL TEST SPEC.
CHEMICA APPROVED GA
L& 1 TEST DRG./REL
CAL TEST SPEC.
BODY,DOOR &
COMPONENT
DRAWING
MACHINING
COMPONENT
HINGE PIN DRAWING
B.2
RING NO LINEAR TEST
INDICATION EPORT
BY PASS COMPONENT
VALVES DRAWING
921
100% By & 10%
APPROVED GA Leakage through the
COMPLETE BODY HYDRO TEST By TEST REPORT P W
DRAWING/REL shell [ Seepage on body
ASSEMBLED CLIENT/Agency
not allowed]
NON RETURN SEAT HYDRO No Leakage Through
C.1 HYDRO TEST -- Do -- -- Do -- TEST REPORT P W
VALVE LEAKAGE TEST Seat
[ BEFORE
PAINTING ] 01 No. of Each No Visually permanent
Disc strength Test Size & Rating per -- Do -- deformation. Leakage TEST REPORT P W
project permitted
COMPLETE
OVERALL
ASSEMBLED
DIMENSION 100% By & 10% APPROVED GA
NON RETURN APPROVED GA DIMENSIONAL
C.2 Verification of MEASUREMENT/Visual By DRAWING/Data P R
VALVE DRAWING/Data sheet REPORT
Heat no./Flow CLIENT/Agency sheet
[ BEFORE
direction
PAINTING ]
COMPLETE
PAINTING/Tag
ASSEMBLED PROCEDURE/Data PROCEDURE/Data COMPLINCE
C.3 marking/Name PAINTING/ visual 100% P R
NON RETURN sheet sheet CERTIFICATE
plate visual
VALVE
922
Specification For Cast Iron Sluice Valve OF Size 100 to 1200 mm
12.54 Specifications For Cast Iron Sluice Valve OF Size 100 to 1200 mm (Item No. LIPDN 63)

Providing, supplying & erecting of CI double flange sluice valve confirming for IS-14846
including worm gear arrangements as per test pressure stainless steel spindle, caps Including
transportation, inspection, unloading, loading, stacking excluding GST levied by GOI &
Providing, supplying & erecting of double flange Cast Iron non-rising spindle soft seated
resilient seated sluice Valves in accordance with IS 14846 of PN-10 / 16 rated, with Body
and bonnet of cast Iron fully encapsulated high quality WRAS or DVGW approved EPDM
rubber (approved for drinking water), Replaceable Wedge nut of Brass, Shaft of Stainless
Steel EN1.4105. Body & Bonnet coated inside & outside with electro-statically applied epoxy
powder coated blue colour RAL 5017 (suitable for drinking water) to DIN 30677-2 & GSK
guidelines with a coating thickness of min. 250 microns. Valves should be full bore & 100%
tight shut-off. Flange drilling as per IS 1538 raised face. Gate valve shall be compatible for
buried applications without valve chamber. Manual operation by Handwheel. Operating
torque shall be less than that mentioned in EN 1171. Testing shall be as per BS 5163 / EN
12266-1&2 / IS 14846.
1 Bonnet, dome, stool cover, wedge, stuffing Cast Iron IS 210 FG200
box, gland thrust plate, cap, Hand wheel
2 Stem Stainless steel IS 6603 12Cr 13 O4Cr

18Ni 10 / 04Cr 17 Ni 12MO 2
3 Body seat ring, wedge facing ring, bushes, leaded in Bronze IS 318 GR LTB2
wedge nut, shoe, channel


7 Flanges IS 1538
8 Gland packing Jute & hemp IS 5414
9 Gear SGI IS1865 GR500/7
10 Pinion & pinion shaft Wrought carbon steel 1570 Gr
C55Mn75
923
• Typical drawing of Sluice Valve
• Testing
Sluice valve shall be subjected to hydrostatic testing of body & seat. The test duration test
pressure shall be as below. The test conditions will be as per IS 14846. The test shall be
witnessed by Engineer In-Charge or his representative. The material test reports of body,
cover, door & pins should be submitted by manufacturer & same should be reviewed by
Engineer in-Charge.
MPa In minutes
Body 1.5 5
1 PN 1.0
Seat 1 2
Body 2.4 5
2 PN 1.6
Seat 1.6 2
924
• Coating –



925
10. Sample Quality Assurance Plan (QAP may be modified as per direction of Engineer In-charge)
FORMAT
RECORD
Manufacturer
INSP.
REPORT
APPROVED GA
APPROVED GA
Body, dome, MATERIAL SPEC.
SPEC.
wedge
APPROVED GA
APPROVED GA
DRG./REL MTC P R
MATERIAL SPEC.
SPEC.
APPROVED GA
APPROVED GA
A.2 Stem DRG./REL MTC P R
MATERIAL SPEC.
SPEC.
BODY, WEDGE
COMPONENT
B.1 AFTER SURFACE DEFECTS VISUAL 100% -- -- P
DRAWING
MACHINING
COMPONENT
DRAWING
B.2 STEM
NO LINEAR TEST
INDICATION EPORT
926
BODY HYDRO 100% By & 10% APPROVED GA Leakage through the
TEST REPORT P W
COMPLETE TEST By CLIENT/Agency DRAWING/REL shell [ Seepage on body
HYDRO SEAT HYDRO No Leakage Through
C.1 VALVE -- Do -- -- Do -- TEST REPORT P W
TEST LEAKAGE TEST Seat
[ BEFORE
PAINTING ] No Visually permanent
01 No. of Each Size
permitted
OVERALL
COMPLETE
DIMENSION
ASSEMBLED APPROVED GA
Verification MEASUREMENT/ 100% By & 10% APPROVED GA DIMENSIONA
C.2 VALVE DRAWING/Data P R
of Heat Visual By CLIENT/Agency DRAWING/Data sheet L REPORT
[ BEFORE sheet
no./Flow
PAINTING ]
direction
PAINTING/T
COMPLETE
ag PROCEDURE/Data COMPLINCE
C.3 ASSEMBLED PAINTING/ visual 100% PROCEDURE/D P R
marking/Nam sheet CERTIFICATE
VALVE ata sheet
e plate visual
927
Specification For Ductile Iron Sluice Valve OF Size 100 to 1200 mm
12.55 Specifications For Ductile Iron Sluice Valve OF Size 100 to 1200 mm ( Item
No. LIPDN 64)
Providing, supplying & erecting of DI double flange sluice valve confirming for IS-14846
including worm gear arrangements as per test pressure stainless steel spindle, caps Including
transportation, inspection, unloading, loading, stacking excluding GST levied by GOI &
Providing, supplying & erecting of double flange Ductile Iron non-rising spindle soft seated
resilient seated sluice Valves in accordance with IS 14846 of PN-10 / 16 rated, with Body
and bonnet of cast Iron fully encapsulated high quality WRAS or DVGW approved EPDM
rubber (approved for drinking water), Replaceable Wedge nut of Brass, Shaft of Stainless
Steel EN1.4105. Body & Bonnet coated inside & outside with electro-statically applied epoxy
powder coated blue colour RAL 5017 (suitable for drinking water) to DIN 30677-2 & GSK
guidelines with a coating thickness of min. 250 microns. Valves should be full bore & 100%
tight shut-off. Flange drilling as per IS 1538 raised face. Gate valve shall be compatible for
buried applications without valve chamber. Manual operation by Handwheel. Operating
torque shall be less than that mentioned in EN 1171. Testing shall be as per BS 5163 / EN
12266-1&2 / IS 14846.
1 Bonnet, dome, stool cover, wedge, stuffing Ductile Iron IS 1865 Gr. 500/7
box, gland thrust plate, cap, Hand wheel
2 Stem Stainless steel IS 6603 12Cr 13 O4Cr

18Ni 10 / 04Cr 17 Ni 12MO 2
3 Body seat ring, wedge facing ring, bushes, leaded in Bronze IS 318 GR LTB2
wedge nut, shoe, channel


7 Flanges IS 1538
8 Gland packing Jute & hemp IS 5414
9 Gear SGI IS1865 GR500/7
10 Pinion & pinion shaft Wrought carbon steel 1570 Gr
C55Mn75
928
• Typical drawing of Sluice Valve
• Testing
Sluice valve shall be subjected to hydrostatic testing of body & seat. The test duration test
pressure shall be as below. The test conditions will be as per IS 14846. The test shall be
Engineer in-Charge.
929
MPa In minutes
Body 1.5 5
1 PN 1.0
Seat 1 2
Body 2.4 5
2 PN 1.6
Seat 1.6 2
• Coating –


A. 80% of the payment will be released after supply of valves

B. Balance 10% of the payment will be released after erection of valves
C. Balance 10% of the payment will be released after testing & commissioning of
valves
930
13 Sample Quality Assurance Plan (QAP may be modified as per direction of Engineer In-charge)
FORMAT
RECORD
Manufacture
r
INSP.
REPORT
APPROVED GA
APPROVED GA
DRG./REL MTC P R
CASTING: PROPERTIES CAL TEST BAR/HEAT MATERIAL
MATERIAL SPEC.
Body, dome, wedge SPEC.
APPROVED GA
APPROVED GA
DRG./REL MTC P R
MATERIAL SPEC.
SPEC.
APPROVED GA
APPROVED GA
A.2 Stem DRG./REL MTC P R
MATERIAL SPEC.
SPEC.
BODY, WEDGE
COMPONENT
B.1 AFTER SURFACE DEFECTS VISUAL 100% -- -- P
DRAWING
MACHINING
COMPONENT
DRAWING
B.2 STEM
NO LINEAR TEST
INDICATION EPORT
931
No Visually
Detectable Leakage
100% By & 10% By APPROVED GA
BODY HYDRO TEST through the shell [ TEST REPORT P W
CLIENT/Agency DRAWING/REL
COMPLETE Seepage on body not
ASSEMBLED allowed]
C.1 VALVE HYDRO TEST SEAT HYDRO No Leakage Through
[ BEFORE LEAKAGE TEST Seat
PAINTING ] No Visually
01 No. of Each Size & permanent
Rating per project deformation.
Leakage permitted
COMPLETE OVERALL
ASSEMBLED DIMENSION APPROVED GA APPROVED GA
100% By & 10% By DIMENSIONAL
C.2 VALVE Verification of MEASUREMENT/Visual DRAWING/Data DRAWING/Data P R
CLIENT/Agency REPORT
[ BEFORE Heat no./Flow sheet sheet
PAINTING ] direction
COMPLETE PAINTING/Tag
PROCEDURE/Data PROCEDURE/Data COMPLINCE
C.3 ASSEMBLED marking/Name PAINTING/ visual 100% P R
sheet sheet CERTIFICATE
VALVE plate visual
932
Specification For Cast Iron Butterfly Valve OF Size 100 to 1200 mm
12.56 Specification for Cast Iron Butterfly Valve OF Size 100 to 1200 mm ( Item
No. LIPDN 65 )
Providing, supplying & erecting of double flanged short body pattern type manually operated
Butterfly Valve confirming in to IS-13095-1991, Synthetic rubber faced ring secured on disc
by retaining ring with stainless steel screw stub shaft of stainless steel riding in teflon bearing
including transportation, inspection, unloading, loading, stacking excluding GST levied by

This specification covers the requirements for providing & erecting of Cast Iron Double
Flanged Double Eccentric Butterfly Valves in accordance with EN 593 /BS 5155 /IS 13095
/API 609 with Body & disc of Ductile Iron confirming to EN1563/ GGG40 / IS 1865 Gr.
400/12, Body seat of PTFE seated with Stainless Steel backed , disk seat of S.S. AISI 304/316
, Shaft of S.S. AISI 420(Dry Shaft Design , (to ensure 100% drop tight shut off as per EN Std
suitable for drinking water application), Internal fasteners of Stainless Steel . Body & disc
coated inside & outside with electro-statically applied epoxy powder coated blue colour
(suitable for drinking water) to DIN 30677-2 & GSK guidelines with a coating thickness of
min. 250 microns. Valves should be 100% tight shut-off. Leakages not allowed. Flange
drilling as per IS 1538/ IS 9523/ ASME B 16.5 / EN1092-2 raised face. Testing as per EN
12266-1&2. Features required for Butterfly valves will be suitable to water work application
for continuous operation up to 70 degree Celsius as per above general specification or
otherwise the standard BS 5155/ EN593

1 Body, Disc Cast Iron IS 200 FG.210
2 Shaft Stainless steel IS 6603
Gr.12Cr1215 Cr 16 Ni 2
04 Cr 18 Ni 10
04 Cr 17 Ni 12 MO 2
3 Seating rings, seat retaining ring Stainless steel IS 6603
Gr. 04 Cr 18 Ni 10
04 Cr 17 Ni 12 MO 2
933

7 Flanges IS 1538
• Typical drawing of Butterfly Valve
• Testing
Butterfly valve shall be subjected to hydrostatic testing of body & seat. The test duration test
pressure shall be as below. The test conditions will be as per 13095. The test shall be
Engineer in-Charge.
MPa In minutes
Body 1.5 5
1 PN 1.0
Seat 1 2
934
Body 2.4 5
2 PN 1.6
Seat 1.6 2
• Coating –


The break up to payment for supplying, erection & testing ofvalve shall be as under:-

935
13 Sample Quality Assurance Plan (QAP may be modified as per directions of Engineer In-charge)
FORMAT
RECORD
RAW Manufacturer
A CLIENT
MATERIAL
INSP.
REPORT
APPROVED GA
APPROVED GA
DRG./REL MTC P R
CASTING: PROPERTIES CAL TEST BAR/HEAT MATERIAL
A.1 MATERIAL SPEC.
BODY, DISC SPEC.
APPROVED GA
APPROVED GA
DRG./REL MTC P R
MATERIAL SPEC.
SPEC.
APPROVED GA
DRIVE SHAFT APPROVED GA
A.2 & DRG./REL MTC P R
STUB SHAFT MATERIAL SPEC.
SPEC.
CHEMICA APPROVED GA
L& 1 TEST DRG./REL
A.3 SEAT RING MECHANICAL DRG./REL MTC P R
CAL TEST SPEC.
CHEMICA APPROVED GA
CLAMPING L& 1 TEST DRG./REL
RING MECHANI BAR/HEAT MATERIAL
CAL TEST SPEC.
COMPONENT
BODY,DISC & DIMENSIONS VISUAL 100% -- -- P
DRAWING
B.1 SHAFT AFTER
NO LINEAR TEST
MACHINING SURFACE DEFECTS DP TEST 100% ASTM A-165 P R
INDICATION EPORT
936
No Visually
100% By & Detectable Leakage
APPROVED GA
BODY HYDRO TEST 10% By through the shell [ TEST REPORT P W
DRAWING/REL
COMPLETE CLIENT/Agency Seepage on body
C.1 VALVE HYDRO TEST SEAT HYDRO No Leakage
[ BEFORE LEAKAGE TEST Through Seat
PAINTING ] No Visually
01 No. of Each
permanent
Disc strength Test Size & Rating -- Do -- TEST REPORT P W
deformation.
per project
Leakage permitted
COMPLETE OVERALL
ASSEMBLED DIMENSION 100% By & APPROVED GA APPROVED GA
DIMENSIONAL
C.2 VALVE Verification of MEASUREMENT/Visual 10% By DRAWING/Data DRAWING/Data P R
REPORT
[ BEFORE Heat no./Flow CLIENT/Agency sheet sheet
COMPLINCE
C.3 ASSEMBLED marking/Name PAINTING/ visual 100% PROCEDURE/Data PROCEDURE/Data P R
CERTIFICATE
VALVE plate visual sheet sheet
937
Specification For Ductile Iron Butterfly Valve OF Size 100 to 1200 mm
12.57 Specification for Ductile Iron Butterfly Valve OF Size 100 to 1200 mm
Providing, supplying & erecting of double flanged short body pattern type manually operated
ductile iron Butterfly Valve confirming in to IS-13095-1991, Synthetic rubber faced ring
secured on disc by retaining ring with stainless steel screw stub shaft of stainless steel riding
in Teflon bearing including transportation, inspection, unloading, loading, stacking excluding
GST levied by GOI & GOM in all respect etc. complete.
This specification covers the requirements for providing & erecting of Ductile Iron Double
Flanged Double Eccentric Butterfly Valves in accordance with EN 593 /BS 5155 /IS 13095
/API 609 with Body & disc of Ductile Iron confirming to EN1563/ GGG40 / IS 1865 Gr.
400/12, Body seat of PTFE seated with Stainless Steel backed , disk seat of S.S. AISI 304/316
, Shaft of S.S. AISI 420(Dry Shaft Design , (to ensure 100% drop tight shut off as per EN Std
suitable for drinking water application), Internal fasteners of Stainless Steel . Body & disc
coated inside & outside with electro-statically applied epoxy powder coated blue colour
(suitable for drinking water) to DIN 30677-2 & GSK guidelines with a coating thickness of
min. 250 microns. Valves should be 100% tight shut-off. Leakages not allowed. Flange
drilling as per IS 1538/ IS 9523/ ASME B 16.5 / EN1092-2 raised face. Testing as per EN
12266-1&2. Features required for Butterfly valves will be suitable to water work application
for continuous operation up to 70 degree Celsius as per above general specification or
otherwise the standard BS 5155/ EN593

1 Body, Disc Ductile Iron IS 1865 Gr. 500/7
2 Shaft Stainless steel IS 6603
Gr.12Cr1215 Cr 16 Ni 2
04 Cr 18 Ni 10
04 Cr 17 Ni 12 MO 2
3 Seating rings, seat retaining ring Stainless steel IS 6603
Gr. 04 Cr 18 Ni 10
04 Cr 17 Ni 12 MO 2
938

7 Flanges IS 1538
• Typical drawing of Butterfly Valve
• Testing
Each valve shall be subjected to hydrostatic testing of body & seat. The test duration test
pressure shall be as below. The test conditions will be as per 13095. The test shall be
Engineer in-Charge.
939
MPa In minutes
Body 1.5 5
1 PN 1.0
Seat 1 2
Body 2.4 5
2 PN 1.6
Seat 1.6 2
• Coating –



940
FORMAT
RECORD
A RAW MATERIAL Manufacturer CLIENT
INSP.
REPORT
APPROVED GA
APPROVED GA
DRG./REL MTC P R
A. CASTING: PROPERTIES CAL TEST BAR/HEAT MATERIAL
MATERIAL SPEC.
1 BODY, DISC SPEC.
APPROVED GA
APPROVED GA
DRG./REL MTC P R
MATERIAL SPEC.
SPEC.
APPROVED GA
APPROVED GA
DRIVE SHAFT & MECHANICAL MECHANI 1 TEST DRG./REL
A.2 DRG./REL MTC P R
STUB SHAFT PROPERTIES CAL TEST BAR/HEAT MATERIAL
MATERIAL SPEC.
SPEC.
CHEMICA APPROVED GA
L& 1 TEST DRG./REL
A.3 SEAT RING MECHANICAL DRG./REL MTC P R
CAL TEST SPEC.
CHEMICA APPROVED GA
L& 1 TEST DRG./REL
A.4 CLAMPING RING MECHANICAL DRG./REL MTC P R
CAL TEST SPEC.
COMPONENT
BODY,DISC & DIMENSIONS VISUAL 100% -- -- P
DRAWING
B.1 SHAFT AFTER
NO LINEAR TEST
MACHINING SURFACE DEFECTS DP TEST 100% ASTM A-165 P R
INDICATION EPORT
941
100% By & 10% APPROVED GA Leakage through the
BODY HYDRO TEST TEST REPORT P W
COMPLETE By CLIENT/Agency DRAWING/REL shell [ Seepage on body
C.1 VALVE HYDRO TEST SEAT HYDRO No Leakage Through
[ BEFORE LEAKAGE TEST Seat
PAINTING ] No Visually permanent
01 No. of Each Size
permitted
COMPLETE OVERALL
ASSEMBLED DIMENSION APPROVED GA
100% By & 10% APPROVED GA DIMENSIONAL
C.2 VALVE Verification of MEASUREMENT/Visual DRAWING/Data P R
By CLIENT/Agency DRAWING/Data sheet REPORT
[ BEFORE Heat no./Flow sheet
PROCEDURE/Data PROCEDURE/Data COMPLINCE
C.3 ASSEMBLED marking/Name PAINTING/ visual 100% P R
sheet sheet CERTIFICATE
VALVE plate visual
942
Specification For Cast Iron Double flanged Air Valve
12.58 Specification For Cast Iron Double flanged Air Valve (Item No. LIPDN 67)
Providing, supplying & erecting of Air Valves confirming IS-14845-2000 and standard
specifications double orifice type combined with isolating sluice valve, mounted in horizontal
position and operated by wheel gearing, small orifice elastic ball resting on a gun metal
orifice nipple, large orifice vulcanite ball seating on moulded seat ring, inlet face and drilled,
including transportation, inspection, unloading, loading, stacking excluding GST levied by
This specification covers the requirements for Providing, supplying & erecting of Air
Valves confirming IS-14845-2000 and standard specifications double orifice type combined
with isolating sluice valve, mounted in horizontal position and operated by wheel gearing,
small orifice elastic ball resting on a gun metal orifice nipple, large orifice vulcanite ball
seating on moulded seat ring, inlet face and drilled, including transportation, inspection,
unloading, loading, stacking excluding GST levied by GOI & GOM in all respect etc.
complete.

1 Body, cover, valve disc, stuffing box, Cast Iron IS 210 FG 200
valve guide, cowl, gland, cap, joint
support ring
2 Low pressure seat ring and face ring Natural rubber IS 11855
3 High pressure orifice, stem nut, body seal leaded in Bronze IS 318 GR LTB2
ring, float guide


7 Flanges IS 1538
8 Float (Low pressure orifice) Timber core with vulcanite coating
9 Float (High pressure Orifice) Timber core With rubber coating
Classification of valves –These valves are classified on the basis of nominal pressure (PN) defined
as maximum gauge working pressure (MPa).
943
PN1.6 - Maximum gauge working pressure- 1.6
1.0 Typical drawing of double float Air Valve
944
2.0 Typical drawing of double float
Each valve shall be subjected to hydrostatic testing of body & seat. The test duration test
pressure shall be as below. The test conditions will be as per IS 14845-2000. The test shall be
witnessed by Engineer In-Charge or his representative.
MPa In minutes
Body 1.5 5
1 PN 1.0
Seat 1 2
Body 2.4 5
2 PN 1.6
Seat 1.6 2
3.0 Coating –



945
Sample Quality Assurance Plan (QAP may be modified as per direction of Engineer In-charge)
FORMAT
RECORD
Manufacturer
INSP.
REPORT
AIR VALVE
APPROVED GA
CASTING: APPROVED GA
BODY ,COVER, DRG./REL MTC P R
ISOLATING MATERIAL SPEC.
SPEC.
SLUICE VALVE
APPROVED GA
BODY, BONNET & APPROVED GA
WEDGE. DRG./REL MTC P R
MATERIAL SPEC.
SPEC.
APPROVED GA
APPROVED GA
AIR VALVE CHEMICAL CHEMICA 1 TEST DRG./REL
DRG./REL MTC P R
NOZZLE PROPERTIES L TEST BAR/HEAT MATERIAL
MATERIAL SPEC.
SPEC.
ISOLATING APPROVED GA
APPROVED GA
SLUICE VALVE CHEMICAL CHEMICA 1 TEST DRG./REL
DRG./REL MTC P R
BODY & WEDGE PROPERTIES L TEST BAR/HEAT MATERIAL
MATERIAL SPEC.
FACE RING SPEC.
AIR VALVE
CASTING
BODY
,COVER,ISOLATIN MEASUR MANUFACTURING MANUFACTUR INSP.
DIMENSIONS 100% P R
G SLUICE VALVE EMENT DRAWING ING DRAWING REPORT
BODY, BONNET &
WEDGE AFTER
MACHINING
C FINAL INSPECTION
946
VISUAL & MEASUR MANUFACTURING MANUFACTUR INSP.
100% P W
DIMENSIONS EMENT DRAWING ING DRAWING REPORT
APPROVED GA APPROVED GA TEST
HYDROSTATIC HYDRO
COMPLETED 10% DRG./ DATA DRG./ DATA CERTIFI P W
BODY TEST TEST
VALVE SHEET SHEET CATE
FUNCTIONAL TEST APPROVED GA APPROVED GA TEST
OPERATI
( FOR ISOLATING 10% DRG./ DATA DRG./ DATA CERTIFI P W
ON
SLV) SHEET SHEET CATE
947
Specification For Cast Iron Kinetic Air Valve
12.59 Specification For Cast Iron Kinetic Air Valve ( Item No. LIPDN 68 )
Providing, supplying & erecting of Kinetic Double Orifice type Air Valves confirming to IS
14845 & as per standard specifications combined with screw down isolating valve, small
orifice elastic ball resting on a gun metal orifice nipple, large orifice vulcanite ball seating on
moulded seat ring, inlet face and drilled, including transportation, inspection, unloading,
loading, stacking excluding GST levied by GOI & GOM in all respect etc. complete.
This specification covers the requirements for Providing, supplying & erecting of Kinetic Air
Valves confirming IS-14845-2000 and standard specifications double orifice type combined
with isolating sluice valve, mounted in horizontal position and operated by wheel gearing,
small orifice elastic ball resting on a gun metal orifice nipple, large orifice vulcanite ball
seating on moulded seat ring, inlet face and drilled, including transportation, inspection,
unloading, loading, stacking excluding GST levied by GOI & GOM in all respect etc.
complete.
1 Body, cover, valve disc, stuffing box, Cast Iron IS 210 FG 200
valve guide, cowl, gland, cap, joint
support ring
2 Low pressure seat ring and face ring Natural rubber IS 11855
3 High pressure orifice, stem nut, body seal leaded in Bronze IS 318 GR LTB2
ring, float guide


7 Flanges IS 1538
8 Float (Low pressure orifice) Timber core with vulcanite coating
9 Float (High pressure Orifice) Timber core With rubber coating
948
• Typical drawing of Kinetic Air Valve
• Testing
The valve shall be fitted on the test bench & pressure of the water in pipe shall be developed
to working pressure, and the main valve or cock shall be gradually opened to check the air
release and float function. Compressed air shall then be slowly injected into the valve through
underside of the valve to check the function of the floats. In case of large orifice single air
valve the pressure of the water in the pipe shall be developed to working pressure. The float
shall automatically lift and seal against the seal. There shall be no sign of leakage.
• High Pressure Orifice Seat Test

Subsequent to high pressure orifice performance test, hydraulic pressure shall be
reduced up to half of the working pressure to check leakage of orifice seat for a
duration of three minutes.
949
• Low Pressure Orifice Seat Test
Subsequent to high pressure orifice performance test, hydraulic pressure shall be
reduced up to half of the working pressure to check leakage of orifice seat for a
duration of three minutes
MPa In minutes
Body 1.5 5
1 PN 1.0
Seat 1 2
Body 2.4 5
2 PN 1.6
Seat 1.6 2
• Coating –



950
Sample Quality Assurance Plan ( QAP may be modified as per direction of Engineer In-Charge)
FORMAT
RECORD
Manufacturer
INSP.
REPORT
AIR VALVE
APPROVED GA
CASTING: APPROVED GA
BODY DRG./REL MTC P R
,COVER,ISOLATIN MATERIAL SPEC.
SPEC.
G SLUICE VALVE
APPROVED GA
BODY, BONNET & APPROVED GA
WEDGE. DRG./REL MTC P R
MATERIAL SPEC.
SPEC.
APPROVED GA
APPROVED GA
AIR VALVE CHEMICAL CHEMICA 1 TEST DRG./REL
DRG./REL MTC P R
NOZZLE PROPERTIES L TEST BAR/HEAT MATERIAL
MATERIAL SPEC.
SPEC.
ISOLATING APPROVED GA
APPROVED GA
SLUICE VALVE CHEMICAL CHEMICA 1 TEST DRG./REL
DRG./REL MTC P R
BODY & WEDGE PROPERTIES L TEST BAR/HEAT MATERIAL
MATERIAL SPEC.
FACE RING SPEC.
AIR VALVE
CASTING
BODY
,COVER,ISOLATIN MEASUR MANUFACTURING MANUFACTUR INSP.
DIMENSIONS 100% P R
G SLUICE VALVE EMENT DRAWING ING DRAWING REPORT
BODY, BONNET &
WEDGE AFTER
MACHINING
951
C FINAL INSPECTION
VISUAL & MEASUR MANUFACTURING MANUFACTUR INSP.
100% P W
DIMENSIONS EMENT DRAWING ING DRAWING REPORT
APPROVED GA APPROVED GA TEST
HYDROSTATIC HYDRO
COMPLETED 10% DRG./ DATA DRG./ DATA CERTIFI P W
BODY TEST TEST
VALVE SHEET SHEET CATE
FUNCTIONAL TEST APPROVED GA APPROVED GA TEST
OPERATI
( FOR ISOLATING 10% DRG./ DATA DRG./ DATA CERTIFI P W
ON
SLV) SHEET SHEET CATE
952
Specification For Electric Actuators With Integral Starter Controls
12.60 Specification For Electric Actuators With Integral Starter Controls

(Item No. LIPDN 69 )
Actuators shall be suitable for the medium, climatic, environmental and pressure
conditions of the system in which they are to be fitted.

This specification covers the requirements for providing, erection & testing of Electrical
Actuator of following components, technical specification and scope of work excluding
GST levied by GOI & GOM in all respect including Third party inspection charges of
TPI Agency approved by WRD including Transit insurance, Railway Freight,
Unloading from railway wagon, Loading into Truck, Transportation to departmental
store, unloading, stacking etc. completed as directed by Engineer-in-charge.
Components of Electrical Actuator
Actuators shall be provided with:
1. AC Electric Motor.
2. Reduction gear unit.
3. Torque switch mechanism.
4. Limit switch mechanism complete with set of limit switches for OPEN and CLOSE
limits and additional two spare sets for suitable intermediate position. All switches shall
have 2NO+2NC type contacts,
5. Hand wheel, for manual operation.
6. Valve position indicator.
7. Hand-auto lever with suitable locking arrangement.
8. Space Heater suitable for single phase supply, in the switch compartment.
9. Electronic position transmitter for remote position feedback in the form of 4 to 20 ma
10.Inbuilt terminal box for terminating power and control cables.
11. With additional accessories for integrating directly with PLC system.
Technical Specifications, Requirements and detail scope of work.

1. Actuator should be suitable for 24VDC digital command signal (OPEN-STOP-
CLOSE) from PLC/DCS. 24VDC Digital command signal shall be isolated from the
control electronics through opto-Isolator.
953
2. The actuator shall be suitable for ON-FF duty as well as Inching duty Operation
on 415V, 3 phase, 50 Hz power supply. The motor shall be short time duty motors (high
starting torque and low Inertia type motors) having min. S2-15 minutes duty. Motor
winding insulation shall conform to class ‘F’ with temp rise limited to class ‘B’ as per
relevant IS/IEC and motor shall be protected by suitable thermal cut out relays. The
actuator shall be capable of producing not less than 1 1/2 times the required operator
torque at the required time cycle of valve operation.
3. The electric motors shall be of the squirrel cage type as per IS 325/IEC60034
with TESC (Totally enclosed surface cooled) type enclosure and insulation to IS
1271/IEC60034 Class‘F’ with temp rise limited Class ‘B’. The windings shall be
impregnated to render them non-hygroscopic and oil resistant. All internal metal parts
shall be painted. The motor shall be rated for 15 minutes. They shall also be suitable for
operating on the specified electric supply and shall satisfactorily open and close the
valve under variations of electric supply specified.
4. Motor shall be protected by suitable overload protection device. The reversing

contactor starter and local controls shall be integral with the valve actuator. The starter
shall comprise mechanically and electrically interlocked reversing contactors of
appropriate rating fed from a 110 or 230V Volt control transformer. Actuators shall
have suitable primary/secondary fuses to protect the internal electronics of the
actuators.
5. Actuator Integral Local control shall comprise pushbuttons for open, close and
stop operations and a Lockable Local/Remote/off selector switch. Actuator starter unit
shall have electronic control logic within built LED’s, visible from outside to show the
various fault and status annunciations of actuators for easy diagnosis and repair of the
actuator. The control schematics diagram of actuator shall be submitted for approval.
6. Internal wiring shall be of 650/1100 volt grade PVC insulated stranded copper
conductor of minimum 0.75 sq. mm for control circuits and of minimum 2.5 sq.mm
copper for the power circuit. Each wire shall be number identified at each end. The
terminals shall be of Screw/stud or plug in type. Cable entries shall be suitable for PVC
insulated/ sheathed, armoured cables.
7. The actuator enclosure shall be fully weatherproof and water proof to IP 68 and
shall be fitted with an anti-condensation heater, which shall be switched off when the
motor is running.
8. The torque switch mechanism shall function as follows to stop the motor on
closing or opening of the valve, or upon actuation by the torque when the valve disc is
restricted in its attempt to open or close. Torque switch dial shall be graduated for the
defined actuator torque value for easy setting to desired value within the range
specified.
954
9. The torque switch in the closing direction shall interrupt the control circuit if
mechanical overload occurs during the closing cycle or when the valve is fully closed.
10. The torque switch in the opening direction shall interrupt the control circuit if
mechanical overload occurs during the opening cycle or when the valve is fully open.
11. The mechanism shall facilitate adjustment of the torque at which the switches are
required to operate. Torque switch shall have 2NO+2NC type potential free contacts
12. Non-adjustable limit switches shall stop the motor and give indication when the
disc has attained the fully open or closed position and shall have 2NO+2NC type
potential free Contacts.
13. The adjustable limit switches shall have control rated 0.46A/5A @240VADC/AC
for specified system interlock, at the desired valve position in both the opening and
closing directions.
14. Motor operators shall be provided with clearly visible local valve position
indicators mounted on the operator assembly to give an indication whether the valve is
fully open, fully closed or in an intermediate position.
15. Actuator shall have hand wheel for emergency operation in case of power failure.
The Hand wheel shall have drive mechanically independent of the motor drive and be
such as to permit emergency manual operation in a reasonable time. During electric
operation the hand wheel shall not rotate.
16. Actuator shall have following minimum potential free type status and fault
feedback contacts available on actuator
- Full OPEN
- Full CLOSE
- Intermediate OPEN
- Intermediate CLOSE
- Torque switch OPEN
- Torque switch CLOSE
- Selector switch in LOCAL/OFF/REMOTE mode
- Collective fault Indication for Thermo switch trip/Torque switch trip
- Analogue position Feedback signal (4 to 20 ma), position transmitter
17. Actuators shall be adjusted at the manufacturer’s work to ensure that they provide
correct, fully, open position and fully closed position. Mechanical adjustable limit
switches shall ensure the prevention of over-travel of the valve in the open and close
positions.
955
18. Actuators shall be tested at manufacture’s work for routine tests on Motor as per
IEC60034, Functional test of actuator and accessories, Output shaft speed and output
torque test etc.


The break up to payment for supplying, erection & testing of Electrical Actuator shall
be as under:-
A) 80% of the payment will be released after supply of Actuator

B) Balance 10% of the payment will be released after erection of Actuator
C) Balance 10% of the payment will be released after testing & commissioning of
Actuator
956
957
0
958
Specification For Dismantling Joint OF Size 100 to 1200 mm
12.61 Specification For Dismantling Joint OF Size 100 to 1200 mm


Providing, erecting & testing of approved make Dismantling Joint of proposed diameterwith
technical specifications as below
i. Design, manufacturing & testing Including transportation, inspection, unloading, loading,
stacking excluding GST levied by GOI & GOM in all respect etc. complete.

This specification covers the requirements for providing, erection & testing of Dismantling
Joint of proposed diameters inclusive cost of jointing materials (fasteners, Neoprene Rubber
gasket etc.) excluding GST levied by GOI & GOM in all respect including Third party
inspection charges of TPI Agency approved by WRD including Transit insurance, Railway
Freight, Unloading from railway wagon, Loading into Truck, Transportation to departmental
store, unloading, stacking etc. completed as directed by Engineer-in-charge

Sr. No. Component IS codes
1 MAIN SHELL PIPE, PRESSING IS-2062 E250 BR
SHELL PIPE, ADAPTOR FLANGE,
FOLLOWER FLANGE, SLIDING
FLANGE, COMPANION FLANGE
2 O RING EPDM RUBBER Hardness 60 to 70

3 STUDS & NUTS IS 1367 4.6 / 4.8 Gr. GI PLATED
4 Flanges IS 1538
1 Classification of Dismantling Joint –
These Dismantling Joint are classified on the basis of nominal pressure (PN) defined as
maximum gauge working pressure (MPa).
959
2Typical drawing of Dismantling Joint
3Testing
Dismantling Joint shall be subjected to hydrostatic testing of body & seat. The test duration
test pressure shall be as below. The test shall be witnessed by Engineer In-Charge or his
representative. The material test reports of various components should be submitted by
manufacturer & same should be reviewed by Engineer in-Charge.
MPa In minutes
Whole
1 PN 1.0 1.5 5
Assembly
Whole
2 PN 1.6 2.4 5
Assembly
4 Coating –
All coatings shall be carried out after satisfactory testing of the Dismantling Joint prior to
dispatch. All exposed body parts must be painted with inside black epoxy & outside grey
epoxy paint or as per directions of Engineer In Charge.

● The net quantity of Dismantling Joint shall be measured on number basis
960
replacement for such Dismantle Joint has to be made by the Contractor without any
extra cost as directed by the Engineer-in-Charge.

The break up to payment for supplying, erection & testing of Dismantling Joint shall be as
under:-
A) 80% of the payment will be released after supply of Dismantling Joint

B) Balance 10% of the payment will be released after erection of Dismantle Joint Balance
10% of the payment will be released after testing & commissioning of Dismantling Joint
961
PROJECT DETAILS
SAMPLE QUALITY ASSURANCE PLAN QAP NO.
DESCRIPTION QTY REV.:
DATE:
1. DISMANTLING JOINTS – DIA NOS PAGE NO: 01 of 01
QUANTUM REFERENC AGENCY
SR. COMPONENTS & CHARACTERISTICS TYPE OF ACCEPTAN FORMAT OF REMARKS
OF E
NO OPERATIONS CHECK CE NORM RECORD M S C
CHECK DOCUMENT
1 2 3 4 5 6 7 8 9 10
1.0 Raw Material Inspection
Mechanical & One Sample IS 2062 E 250 Relevant MILL TC/

1.1 Plates Mechanical & Chemical P R R
Chemical check per Heat/lot BR Specification Lab TC
1.2 Plate UT(T≥40 mm) Internal defects UT Per plate ASME SEC V ASTM A 435 UT Report P R R
2.0 In process inspection

Qualification ASME SEC Relevant WPS/PQR/
2.1 Welding (SMAW) WPS/PQR/WPQ 100% P R R
Verification IX Specification WPQ
NO
2.2 NDT DPT NDT 100% ASTME -165 DP REPORT P R R
INDICATION
3.0 Final Inspection

FINAL DIMN.REPOR
3.1 Visual & Dimensional Measure 100 % AS PER DRAWING P W R
INSPECTION T
Hydro test pressure
Hydro Test 37.5kg/cm2.
3.2 Hydro test Weld Soundness Visual 100% IS:3589 P W R
report Holding time: 30
Mins.
MANUFACTURER/ SUB
MAIN SUPPLIER LEGEND: FOR CLIENT USE : DOC. NO. :
SUPPLIER
M : MANUFACTURER/ SUB
SUPPLIER
S : MAIN SUPPLIER
C : CLIENT
P : PERFORM
962
PROJECT DETAILS
DATE:
1. DISMANTLING JOINTS – DIA NOS PAGE NO: 01 of 01
OF E
CHECK DOCUMENT
W : WITNESS
R : REVIEW
SIGNATURE REVIEWED BY
963
Specification For Dismantling Joint OF Size 100 to 1200 mm
12.62 Specification For Expansion Joint OF Size 100 to 1200 mm

Providing, erecting & testing of approved make Expansion Joint of proposed diameter with
technical specifications as below :
i. Design, manufacturing & testing Including transportation, inspection, unloading, loading,
stacking excluding GST levied by GOI & GOM in all respect etc. complete.

This specification covers the requirements for providing, erection & testing of Expansion
Joint of proposed diameters inclusive cost of jointing materials (fasteners, Neoprene Rubber
gasket etc.) excluding GST levied by GOI & GOM in all respect including Third party
inspection charges of TPI Agency approved by WRD including Transit insurance, Railway
Freight, Unloading from railway wagon, Loading into Truck, Transportation to departmental
store, unloading, stacking etc. completed as directed by Engineer-in-charge

Sr. No. Component IS codes
1 MAIN SHELL PIPE, PRESSING IS-2062 E250 BR
SHELL PIPE, ADAPTOR FLANGE,
FOLLOWER FLANGE, SLIDING
FLANGE, COMPANION FLANGE
2 O RING EPDM RUBBER Hardness 60 to 70

3 STUDS & NUTS IS 1367 4.6 / 4.8 Gr. GI PLATED
4 Flanges IS 1538
• Classification of Expansion Joint –
These Expansion Joint are classified on the basis of nominal pressure (PN) defined as
maximum gauge working pressure (MPa).
964
1 Typical drawing of Expansion Joint
• Testing
Expansion Joint shall be subjected to hydrostatic testing of body & seat. The test duration test
pressure shall be as below. The test shall be witnessed by Engineer In-Charge or his
representative. The material test reports of various components should be submitted by
manufacturer & same should be reviewed by Engineer in-Charge.
MPa In minutes
Whole
1 PN 1.0 1.5 5
Assembly
Whole
2 PN 1.6 2.4 5
Assembly
965
• Coating –
All coatings shall be carried out after satisfactory testing of the Expansion Joint prior to
dispatch. All exposed body parts must be painted with inside black epoxy & outside grey
epoxy paint or as per directions of Engineer In Charge.

● The net quantity of Expansion Joint shall be measured on number basis
replacement for such Dismantle Joint has to be made by the Contractor without any
extra cost as directed by the Engineer-in-Charge.

The break up to payment for supplying, erection & testing of Expansion Joint shall be as
under:-
C) 80% of the payment will be released after supply of Expansion Joint

D) Balance 10% of the payment will be released after erection of Dismantle Joint Balance
10% of the payment will be released after testing & commissioning of Expansion Joint
966
PROJECT DETAILS
DATE:
2. Expansion JOINTS – DIA NOS PAGE NO: 01 of 01
OF E
CHECK DOCUMENT
1 2 3 4 5 6 7 8 9 10
1.0 Raw Material Inspection
Mechanical & One Sample IS 2062 E 250 Relevant MILL TC/
1.1 Plates Mechanical & Chemical P R R
Chemical check per Heat/lot BR Specification Lab TC
1.2 Plate UT(T≥40 mm) Internal defects UT Per plate ASME SEC V ASTM A 435 UT Report P R R
2.0 In process inspection
Qualification ASME SEC Relevant WPS/PQR/

2.1 Welding (SMAW) WPS/PQR/WPQ 100% P R R
Verification IX Specification WPQ
NO
2.2 NDT DPT NDT 100% ASTME -165 DP REPORT P R R
INDICATION
3.0 Final Inspection
FINAL DIMN.REPOR
3.1 Visual & Dimensional Measure 100 % AS PER DRAWING P W R
INSPECTION T
Hydro test
pressure
Hydro Test
3.2 Hydro test Weld Soundness Visual 100% IS:3589 P W R 37.5kg/cm2.
report
Holding time:
30 Mins.
MANUFACTURER/ SUB
MAIN SUPPLIER LEGEND: FOR CLIENT USE : DOC. NO. :
SUPPLIER
967
PROJECT DETAILS
DATE:
2. Expansion JOINTS – DIA NOS PAGE NO: 01 of 01
OF E
CHECK DOCUMENT
M : MANUFACTURER/ SUB
SUPPLIER
S : MAIN SUPPLIER
C : CLIENT
P : PERFORM
W : WITNESS
R : REVIEW
SIGNATURE REVIEWED BY
968

WRD CSR 2022-23 (Specification)

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

WRD CSR 2022-23 (Specification)

Uploaded by

Copyright:

Available Formats

GOVERNMENT OF MAHARASHTRA

WATER RESOURCES DEPARTMENT

COMMON SCHEDULE OF RATES

WATER RESOURCES DEPARTMENT

COMMON SCHEDULE OF RATES FOR 2022-23

Lead Charges Statement for Materials

SECTION-5 295 382

SECTION-6 383 389

SECTION-7 ------ ------

7.0 Valuation of Rehabilitation Works

SECTION-9 401 423

SECTION-10 424 448

SECTION-11 449 501

SECTION-12 502 968

Section No Name Of Section

Section 8 Flow Measuring Devices

Section 9 Marking Blue Line & Red Line

Section 10 Land Reclamation Work & Soil Survey

2.1 EXCAVATION IN SOFT AND HARD STRATA (ITEM NO. EW 1-EW 6)

2.1.1 DESCRIPTION OF ITEM:-

2.1.2 SCOPE OF WORK

2.1.3 QUALITY ASSURANCE

2.1.4 LINE OUT

Profile of designed canal reaches may be marked out at closer intervals of 10 m on

2.1.5 ACCURACY OF ALIGNMENTS, GRADES, LEVELS ETC:

c) Hard murum and boulder :

2.1.8 EXCAVATION IN ROCK

2.1.8.1 Removal of loose rock:

2.1.9.2 Materials, Tools and Equipment

2.1.10 WORKING UNDER WET CONDITONS:

2.1.11 DISPOSAL OF EXCAVATED MATERIAL:

2.1.17 CONTROLLED BLASTING

2.1.19 PAY LINE

2. Canal : CBL and cut off statement

3. Cross sections (with references of the benchmarks and field books.)

Canal section shall be excavated as shown on drawing or as directed by the Engineer-in-

a) For sides, pay line shall be limited to 15 cm in average.

ii) For bed:

Pay line in case of bed shall be

strata, no pay line is admissible.

2.1.19.2 Excavation for dam and other structures :

a) Soft Strata : 1:1

b) Hard strata : 0.25:1

c) Berms with Prior approval.

2.1.20 SORTING OF MATERIALS

2.1.20.2 Hard Strata:

2.1.20.3 Conveyance of Material :

2.1.21 STACKING AND DISPOSAL OF EXCAVATED MATERIAL

2.1.21.2 Stacking and utilizing useful material :

2.1.21.3 Disposal of surplus material :

Spoils banks shall be formed beyond 50 m distance from the

edge of embankment. In case of canal and canal structures :-

2.1.22 SILTING OF EXCAVATION

2.1.23 BOX EXCAVATION

2.1.24 PREPARING AND TESTING OF FOUNDATION

2.1.24.2 Treatment of weak local spots:

2.1.24.3 Final finished surface of foundation:

2.1.24.4 Testing for soundness:

2.1.26 THE RATE OF EXCAVATION WILL INCLUDE

2) Loading the tipper and unloading the muck.

3) Marching away for next blasting and re-location after blasting.

4) Labour and staff required.

c) All applicable taxes, royalty and licensing fees etc.